WO2011123968A1 - 具有塑质结合件的金属薄壳件及其制法 - Google Patents

具有塑质结合件的金属薄壳件及其制法 Download PDF

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Publication number
WO2011123968A1
WO2011123968A1 PCT/CN2010/000437 CN2010000437W WO2011123968A1 WO 2011123968 A1 WO2011123968 A1 WO 2011123968A1 CN 2010000437 W CN2010000437 W CN 2010000437W WO 2011123968 A1 WO2011123968 A1 WO 2011123968A1
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WO
WIPO (PCT)
Prior art keywords
metal
plastic
shell member
metal thin
adhesive layer
Prior art date
Application number
PCT/CN2010/000437
Other languages
English (en)
French (fr)
Inventor
谢明仁
Original Assignee
铂邑科技股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 铂邑科技股份有限公司 filed Critical 铂邑科技股份有限公司
Priority to PCT/CN2010/000437 priority Critical patent/WO2011123968A1/zh
Priority to US13/639,497 priority patent/US8409678B2/en
Publication of WO2011123968A1 publication Critical patent/WO2011123968A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D22/00—Producing hollow articles
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B25/08—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • 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
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/006—Glues or adhesives, e.g. hot melts or thermofusible adhesives
    • 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
    • B29K2995/002—Coloured
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1355—Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1355—Elemental metal containing [e.g., substrate, foil, film, coating, etc.]
    • Y10T428/1359—Three or more layers [continuous layer]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/1386—Natural or synthetic rubber or rubber-like compound containing

Definitions

  • the invention relates to a metal thin shell member with a plastic bond member and a manufacturing method thereof, in particular to a metal surface of a metal thin shell member bonded to a TPR adhesive layer which is composed of a styrene-butadiene block copolymer and a thermoplastic rubber film synthesized by a hydrocarbon petroleum resin, which is then injection molded on the TPR adhesive layer by an injection molding process, so that the pressure and temperature of the injection material during the injection molding are combined with The TPR adhesive layer and the metal thin shell member are combined to form a firmly integrated integrated composite structure.
  • a TPR adhesive layer which is composed of a styrene-butadiene block copolymer and a thermoplastic rubber film synthesized by a hydrocarbon petroleum resin
  • a thin shell member is often used as the outer casing of the product; the thin shell member has a different structure depending on the design requirements of the product, and can be roughly classified according to the material used for the base of a thin shell member. Two main structural categories of plastic thin shell parts and thin metal shell parts.
  • a plastic thin shell member having an outer decorative surface is generally formed by an in-mold decorating process (IMD) which forms a three-dimensionally shaped shape and printed with a patterned substrate such as
  • IMD film IMD ⁇ lm
  • IMD film IMD ⁇ lm
  • a plastic injection molding process is used to project a hot melt resin on the back surface of the IMD film to form the substrate of the casing, hereinafter referred to as the substrate.
  • a resin base the resin matrix is combined with the IMD film to form a bulk plastic shell member, wherein the IMD film can be fixedly bonded to the outer surface of the resin base.
  • the IMD film may be temporarily fixed outside the resin base Forming a temporary device on the surface, the IMD film can be peeled off after completion, and the printed pattern on the IMD film is transferred or left in the appearance of the resin matrix For reference as a decorative surface of the outer shell member of plastic substance.
  • US 3,654,062 discloses a related art of a molded decorative plaque having a laminated facing sheet which is formed by injection molding a hot melt plastic into a mold having a mold configuration. The surface sheet is formed on the back surface.
  • US 6, 117, 384 reveals that using one has more A color-colored film, which is formed by injection molding a hot melt resin on the back side of the film to form a permanently bonded three-dimensional object.
  • US 4,391,954 discloses a correlation between an aromatic carbonate polymer and a thermoplastic thermoplastic molding compound obtained from cyclohexanedimethanol. technology.
  • thermoplastic molding compound polyethylene molding compound
  • US 6,465,102 discloses an article comprising a decorative surface region and an integrally formed polymeric base and a molding method thereof, and the polymeric matrix comprises a transparent cycloaliphatic polyester resin
  • An article comprising a decorative surface area and an acryl particle resin, the cycloal Iphat ic polyester res in is free from an aromatic moiety and the method of molding thereof ).
  • US 6,117,384 discloses an improved technique for in-mold decorating processes (IMD).
  • US 6,136,441 discloses related art of multilayer plastic articles.
  • the prior art mostly uses a plastic film (i.e., IMD film) and a resin matrix contained in a plastic case.
  • Resin base for example, to define a plastic film (IMD film) or a resin matrix (res in base) as a special chemical family plastic material to make a stable bond and not easy to peel off.
  • IMD film plastic film
  • resin matrix resin matrix
  • One-piece composite plastic sheet and can be distinguished from other patents (prior art).
  • a plastic film i.e., IMD film
  • a resin base of a plastic thin-shell article composed of a composite material is specifically defined, not only the materials used but also the materials used are limited.
  • the application of the plastic film (ie, IMD film) and/or the resin base is relatively limited, which is not conducive to the application of the manufactured thin plastic shell member, for example, for diversification needs, including but not limited
  • a cloth, a leather surface, a resin fiber surface or the like is used as a plastic film, it is often impossible to use the same technology or equipment and achieve high productivity, mass production, and good quality control, and it is relatively impossible to upgrade the plastic.
  • the use efficiency and application range of the outer casing can be regarded as the disadvantage of the above-mentioned plastic thin shell members.
  • the more common metal thin-shell member comprises: a thin-shell shape formed by machining a thin metal plate such as an aluminum alloy thin plate, or further surface-treated on the outer surface of the shape of the metal thin-shell member.
  • a resin layer such as a resin film is further disposed on the outer surface of the shape of the metal shell member to protect the outer surface of the metal from being scratched or bumped during use, or further
  • the outer surface of the shape of the metal shell member is further provided with a patterned resin layer for protecting the outer surface of the metal and enhancing the aesthetic or tactile sensation of the product, or using plastic injection molding according to the assembly requirements of the internal components of the product.
  • Technical or injection-molding bonding method (only refers to the molding method by injection molding) directly sets or bonds various plastic fittings for assembly on the inner surface (metal surface) of the shape of the metal thin-shell member Such as flange shape or rib shape, etc., to simplify the structure and overall thickness of the plastic coupling members for assembly, and to enhance the structural strength.
  • ZL02805359.1 discloses a composite of aluminum alloy and resin and a manufacturing method thereof
  • the related art is characterized in that it comprises: an aluminum alloy shape subjected to a contact process, wherein the contacting step is such that the aluminum alloy shape and the dissolution are selected from the group consisting of ammonia, hydrazine (diammine), methylamine and ethylenediamine.
  • the aqueous solution of one or more kinds of compounds is contacted, the step of adsorbing and leaving the aqueous solution on the surface thereof, and the resin integrally attached to the aluminum alloy shape by injection molding, wherein the resin is selected from the group consisting of polyterephthalic acid An alkyl ester, a copolymer mainly comprising the aforementioned polyalkylene terephthalate, and the aforementioned polyalkylene terephthalate
  • the thermoplastic composition in the one or more points.
  • Chinese invention patent application No. ZL200380102886.0 discloses a composite of an aluminum alloy and a resin and a related art thereof, characterized in that it is selected from ammonia An aluminum alloy shaped article impregnated in one or more aqueous solutions of hydrazine (hydrazine) and a water-soluble amine compound, and integrally adhered to the surface of the aluminum alloy shaped article, and having a thermoplasticity of a polyphenylene sulfide component Composition composition.
  • thermoplastic composition is a main component of a butylene carboxylate resin or a polyphenylene sulfide.
  • Chinese invention patent application number ZL200680046075.7 (International application PCT/ JP2006/324493, country WO2 GG7/066742 discloses a related art of a metal resin composite and a method for producing the same, characterized in that it is formed of an aluminum alloy member and a thermoplastic synthetic resin composition member, the aluminum alloy member being the following member: The step of treating at least one aqueous solution selected from the group consisting of ammonia, hydrazine (hydrazine) and a water-soluble amine compound by an electron microscope, the surface of which is covered with a concave portion having a number average inner diameter of 10 to 80 nm, and the thermoplastic synthetic resin composition
  • the member is a member that is fixed to the surface of the aluminum alloy member by injection molding, and the main component of the resin composition is a polyamide resin, and the secondary component is an impact resistance improving material.
  • the surface treatment process of the metal (aluminum alloy) shape and the composition of the resin shape are specifically limited, and relatively complex, so that the process and application of the composite Restricted, it is not conducive to the use efficiency and application range of the thin metal shell member.
  • the use of specially selected aqueous solutions is less in line with current environmental protection requirements.
  • the above metal thin shell articles and their preparation methods have at least the following disadvantages: Designing a single infusion in each injection molding mold with each resin joint In order to perform high-pressure spot injection molding of the resin bonding member, the metal thin-shell member is easily deformed and damaged due to high pressure during the injection molding process, and the difficulty in manufacturing the injection molding die is increased; and the metal surface of the metal thin-shell member is required The impregnation process is first carried out with a special aqueous solution, which results in a complicated process, which is not conducive to mass production of the metal thin shell member, and in particular, the special aqueous solution is more environmentally friendly.
  • the domestic invention patent application No. 85100575 (Announcement No. 404888) "high-precision resin-coated metal sheet having excellent processing adhesion” discloses a related art of a resin-coated metal sheet, which uses a metal plate as a substrate, at least in the On the surface of the substrate, a coating layer, 100 to 20 parts by weight of the polypropylene copolymer, and 100 to 0 parts by weight of the polyacrylonitrile resin layer, pattern or/and Fully printed layer, adhesive layer, 5 ⁇ 100 ⁇ thick polyester resin film (see claim 1); or layered with coating layer, pattern or / and full printed layer, polypropylene copolymer 100 to 20 parts by weight and 100 to 0 parts by weight of polypropylene, 5 to ⁇ ⁇ thick modified acryl resin layer, adhesive layer, 5 to ⁇ thick polyester resin film (see claim 2); or 5 ⁇ ⁇ ⁇ thick denatured acryl resin layer, adhesive layer, 5 - ⁇ ⁇ thick consisting of a coating layer, 100
  • the components of the resin coating layer sequentially laminated on the substrate side have been specifically defined, and the main purpose is that the resin-coated metal sheet has high vividness, and the outer shape of the metal sheet is restricted. It is not conducive to the application of the fabricated metal shell member.
  • a related art for coating a resin metal sheet which includes: The sheet metal piece has an arithmetic mean deviation (Ra) value of roughness between 0 micrometers and 10 micrometers; a transparent soft resin layer comprising an uncured mixed-type resin layer, a coating of a polyester resin a coating, or a polyolefin resin; an adhesive layer comprising a pigment; a transparent resin film having a gloss treated on both sides, wherein at least one of the metal sheets is covered with a colored layer, a soft resin layer, a layer followed by a transparent layer, and each layer is covered with a metal sheet The side to transparent resin film is sequentially covered.
  • Ra arithmetic mean deviation
  • the components of the resin coating layer which are sequentially laminated on the side of the metal sheet have been specifically defined, and the main purpose of the resin-coated metal sheet is to have high vividness, and the shape of the metal sheet is limited, and Conducive to the application of the thin metal parts produced.
  • 404888 is modified to disclose a related art of an aluminum alloy substrate provided with a film layer, the method comprising at least: a "coating adhesive” step on at least one side of a metal substrate made of an aluminum alloy The surface is coated with a layer of an adhesive, and the adhesive has a metal powder; a "baking heating” step of heating the metal substrate of the adhesive to soften the adhesive; a “rolling, step, by The heated roller roll-rolls a film layer on the adhesive layer, wherein the film layer is formed by laminating at least one polyvinyl chloride layer, one adhesive layer and one polyester layer in sequence, and the layer has a metal layer Powder; a "cooling forming” step to bond the film layer to the metal substrate.
  • composition of the laminated film layer is formed by laminating at least one polyvinyl chloride layer, one adhesive layer and one polyester layer in sequence, so that the film layer has been specifically defined, and the shape of the metal substrate is relatively Restricted, it is not conducive to the application of the fabricated metal shell.
  • the structure of the board includes a metal substrate, a composite resin layer applied to the metal substrate and heated and softened, and a metal panel is rolled and laminated on the composite resin layer by a roller to make the metal panel and the metal panel
  • the metal substrate is closely bonded.
  • the second outer surface of the structure of the present invention is a metal plate and a metal substrate. Therefore, there are disadvantages that the two outer sides have been specifically defined.
  • the Chinese Utility Model Patent Application No. 096215339 (Certificate No. M328384) "Environmentally Friendly Skin Metal Structure” discloses a related art of a veneered metal structure, which at least includes: a metal substrate; an adhesive layer coated on the aforementioned metal At least one side surface of the substrate is heated and appropriately softened; and a film layer is formed by sequentially laminating a polyurethane bottom layer and a polyurethane surface layer, and is rolled and laminated on the adhesive layer by a roller and then cooled. The film layer is intimately bonded to the metal substrate.
  • composition of the film layer in the structure of the present invention is formed by sequentially laminating a polyurethane underlayer and a polyurethane surface layer, so that the film layer has been specifically defined, so that the shape or feel of the metal substrate is relatively limited. , is not conducive to the application of the metal thin shell parts produced.
  • the prior art of various composite boards does have some disadvantages, and the present invention is directed to the above-mentioned prior art Chinese invention patents ZL02805359. 1 , ZL200380102886. 0 , ZL200380104500. X and ZL200680046075.
  • the disadvantages of the related art of the composite of metal and resin and the preparation method thereof are effectively solved. Summary of the invention
  • the object of the present invention is to provide a metal thin shell member having a plastic bond member and a method for manufacturing the same, which is provided on a metal surface of a metal thin shell member or a portion where a plastic bond member is to be formed.
  • 400-500 ⁇ TPR adhesive layer the installation method is not limited to coating or spray coating, the TPR is composed of styrene-butadiene block copolymer and thermoplastic resin film synthesized by hydrocarbon resin; this has TPR adhesive layer
  • the thin metal shell member is placed and fixed in a cavity of the injection molding die corresponding to the shape of the metal thin shell member; and the plastic injection molding process is applied to the TPR adhesive layer on the metal surface of the metal thin shell member.
  • a further object of the present invention is to provide a metal thin shell member having a plastic bond member and a method for manufacturing the same, wherein the injection molding process of the plastic bond members is achieved by a general plastic injection molding process, and the injection material is generally injection molded.
  • the pressure and temperature are not only beneficial to the production of the injection molding die, but also can effectively simplify the arrangement and design of the injection flow channel, and the other surface of the metal thin-shell member has a decorative outer coating such as a plating layer and an anodizing treatment.
  • the layer, the lacquer layer, the film layer, and the like are not deformed or damaged by the pressure in the injection molding process, and the practical effect of high production efficiency, easy mass production, cost reduction, and easy control of the molding quality is achieved.
  • a metal thin shell member having a plastic bond member comprising: a metal thin shell member, a TPR adhesive layer and at least one plastic bond member, wherein: the metal thin shell member is a metal substrate of a suitable thickness The metal substrate is naturally produced on the surface layer during the manufacturing process; the TPR adhesive layer is composed of a thermoplastic rubber film synthesized by a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of 400-500 ⁇ .
  • the plastic bonding member is used to insert and fix the metal thin shell member provided with the TPR adhesive layer in the mold cavity of the injection molding mold by using a plastic injection molding process
  • the injection molding material is formed by injection molding on the inner surface of the metal thin shell member; wherein the plastic bonding member is combined with the injection pressure and temperature of the injection material during injection molding to thermally fuse the TPR adhesive layer with each other. Integrating, and at the same time forcing a portion of the thickness of the TPR adhesive layer to penetrate into a plurality of fine recessed holes on the inner surface of the metal thin metal shell member, so that the plasticized material after injection molding
  • the bonding member is combined with the metal thin shell member to form an integrated composite structure.
  • a method for manufacturing a metal thin shell member having a plastic bond member for manufacturing a metal thin shell member having a plastic bond member comprising the steps of: providing a metal thin shell member having a metal substrate of a suitable thickness Formed and formed, and the surface layers of the inner and outer surfaces of the metal substrate have a plurality of fine EJ holes which are nearly uniformly spread; a thickness of 4 00-5 is set on the metal inner surface of the metal thin shell member.
  • the TPR adhesive layer is a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin; and a plastic injection molding process is used to fix the metal thin shell member provided with the TPR adhesive layer Ejecting into the cavity of the molding die such that the injection material is sprayed onto the inner surface of the metal thin shell member and the at least one plastic bonding member is injection molded on the TPR adhesive layer, and the plastic bonding member is ejected by injection molding.
  • the pressure and temperature of the material are integrated with the TPR adhesive layer, and at the same time, the partial thickness of the TPR adhesive layer is forced to penetrate into a plurality of fine recessed holes on the inner surface of the metal thin metal shell member, so that the injection is performed.
  • the plastic bond member of the type is combined with the metal thin shell member to form an integrated composite structure; after being cooled, it is taken out by the injection molding die, that is, a metal thin shell member having a plastic bond member is completed.
  • the invention can simplify the structure of the plastic bonding parts and enhance the structural strength, avoid the disadvantages of the prior art, achieve the purpose of relatively simple process and molding die, high production efficiency, easy mass production, low cost and easy control of molding quality. tube.
  • FIG. 1 is a schematic view showing a manufacturing process of a metal thin shell member having a resin bonded member according to the present invention
  • FIG. 2 is a front perspective view of an embodiment of a metal thin shell member of the present invention.
  • Figure 3 is a rear perspective view of Figure 2;
  • Figure 4 is a cross-sectional view (partially enlarged) of the thin metal shell member shown in Figure 2;
  • Figure 5 is a schematic cross-sectional view of the injection molding die of the present invention, wherein the resin bonding member is fixed on the metal surface of the metal thin shell member by injection molding;
  • Figure 6 is a cross-sectional (partially enlarged) view showing a thin metal shell member having a resin bonded member of the present invention
  • Figure 7 is a perspective view showing a three-dimensional (back view) of an embodiment of a metal thin shell member having a resin bonded member of the present invention.
  • Metal thin shell member 1 having a plastic bond member; metal thin shell member 10; metal substrate 11; inner surface 12; partial portion 12a; outer surface 13; fine recessed hole 14; outer cover layer 15; TPR adhesive layer 20; Molding mold 30; mold cavity 31; upper mold 32; lower mold 33; mold cavity surface 34; filling port 35; injection flow path 36; molding cavity 37; plastic bonding member 40.
  • the method for manufacturing the thin metal shell member 1 having the plastic bond member of the present invention mainly comprises the following steps:
  • a metal thin shell member 10 is provided; the metal thin shell member 10 of the present invention refers to a general product such as a common computer product, a notebook computer, a communication product such as a mobile phone or a consumer. (consumer) 3C product, such as a product, but not limited to the outer casing, here is illustrated by an outer casing of a notebook computer as shown in FIGS.
  • the metal thin shell member 10 includes and is not limited to one a metal substrate 11 of a suitable thickness, such as an aluminum alloy substrate, is processed by a metal thin shell member formed by press working, the metal substrate 11 having an inner surface I 2 and an outer surface 13 , and the inner and outer surfaces I 2 , 13 Table
  • the substrate 1 1 is naturally generated during the manufacturing process, such as rolling, due to the precision relationship of the pressing surface; and the outer surface 13 of the metal substrate 1 1 1 may be subjected to other processing to have a decorative outer covering 15 such as An electroplated layer, an anodized layer, a lacquer layer, a film layer, etc. to increase the external aesthetic appearance of the outer surface 13;
  • a TPR adhesive layer 20 having a thickness of about 400-500 ⁇ m is disposed on the inner surface 12 of the metal thin-walled member 10 on the metal surface-like inner surface 12 or in a portion 12a where the plastic bonding member is to be formed; the TPR adhesive The layer 20 is a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin.
  • the TPR adhesive layer 20 is disposed in a manner not limited, for example, by printing or spraying or by an automatic dispensing device;
  • the metal thin shell member 10 having the TPR adhesive layer 20 is placed and fixed in the cavity 31 of the injection molding die 30 as shown in FIG. 5; the injection molding die 30 is based on the prior art of the plastic injection molding process.
  • the design, the structural type, such as the number of cavity, the position of the filling port, the arrangement of the injection flow channel or the positioning device, etc., is not limited.
  • the general injection molding die 30 shown in FIG. 5 is taken as an example to illustrate the injection molding die.
  • the 30 may include an upper mold 32 and a lower mold 33, but not limited thereto, wherein a cavity surface 34 corresponding to the shape of the metal thin shell member 10 is disposed in the cavity 31 of the lower mold 33 for positioning and fixing the metal a thin shell member 10; the upper mold 32 is provided with a filling port 35 required for injection molding, a shooting material flow path 36, and a molding cavity 37 of each plastic bonding member 40 to be provided, wherein the filling port 35 and the injection material
  • the arrangement of the flow passages 36 is not limited, and the number, position and shape of the molding cavity 37 are not limited, and may be designed according to the needs of use, that is, the number and position of the plastic coupling members 40 of the present invention.
  • the shape and the like are not limited and are not limited, and may be designed as different structures such as a socket and a reinforcing rib.
  • the plastic coupling member 40 is illustrated by a hollow cylindrical receiving seat as shown in FIG. 5-7, and the hollow is as shown in FIG. 5-7.
  • the interior of the cylindrical socket is typically remelted into a metal (eg copper) kit to form a metal socket for strong locking of the fastener;
  • the plastic bonding members 40 are formed on the inner surface 12 of the metal thin shell member 10 and on the TPR adhesive layer 20; and the plastic bonding members 40 can be formed by injection molding.
  • the existing pressure and temperature of the injection material 40a are thermally integrated with the TPR adhesion layer 20, and at the same time, a part of the thickness of the TPR adhesion layer 20 is forced to penetrate into the metal, such as 10% (about 40-50 ⁇ ).
  • the metal inner surface 12 of the thin shell member 10 has a plurality of fine recessed holes 14 therein, so that the injection molded plastic bonding members 40 can be stably disposed on the inner surface 12 of the metal thin shell member 10. , in combination with the metal thin shell member 10 to form a solid combination of the integrated composite structure, that is, the metal thin shell member 1 having the plastic bonded member 40 of the present invention;
  • the above method of the present invention since the TPR adhesive layer 20 can penetrate into the metal during the injection molding process
  • the metal inner surface 12 of the thin shell member 10 has a plurality of fine recessed holes 14 therein, and at the same time is firmly combined with the plastic bond member 40 to form a thin metal joint, thereby forming a thin metal with a plastic bond member.
  • the metal shell member 10 of the shell member 1 and the plastic binder member 40 are capable of maintaining a relatively good adhesion bond.
  • each of the plastic binder members 40 formed on the inner surface 12 has Sufficient resistance to peeling, sufficient to withstand the bonding force of various components applied to the corresponding mating plastic bond 40 in subsequent assembly operations, such as fastening the different components to the plastic bond 40 by means of automated equipment;
  • the plastic bond members 40 have sufficient structural strength and can avoid the disadvantages of the prior art as described above, achieving the purpose of relatively simplified process and molding dies.
  • the present invention is more compatible with current environmental requirements than the prior art described above.
  • the method of the present invention utilizes the metal thin-shell member 10, that is, the metal substrate 11, such as the inner surface recess 14 of the aluminum alloy substrate, so that a portion of the thickness of the TPR adhesive layer 20 can directly penetrate into the fine recessed holes during the injection molding process.
  • the prior art processes such as ZL02805359.1, ZL200380102886.0, ZL200380104500.
  • X and ZL200680046075.7 are required to prepare a special aqueous solution, and the metal substrate is first immersed in the special aqueous solution and the like. Further, the thermoplastic resin having a special composition is molded and adhered to the surface of the metal substrate to cause complicated reproduction and environmental problems.
  • a purification process step may be taken for the surface state of the inner surface 12.
  • the purification treatment step includes, but is not limited to, degreasing, strong brushing, etc., and the main purpose is to maintain the working surface of the inner surface 12 in a certain degree of clean state, so as to avoid a bad operation procedure for the subsequent installation of the TPR adhesion layer 20. The effect is to achieve a good close adhesion between the TPR adhesive layer 20 and the inner surface 12.
  • the plastic bonding members 40 may be Use ABS (styrene resin), PC (polycarbonate resin), Acrylic resin, acrylic resin, Nylon, etc., but not limited to use as injection material during injection molding.
  • ABS injection pressure 80kg/mm 2 injection temperature 200 ° C
  • PC injection pressure 120kg/mm 2 injection temperature 260 ° C
  • Acrylic res in injection pressure 100kg / mm 2 injection temperature 240 ° C
  • Nylon (nylon / polyamide resin) injection pressure 80kg / hidden 2 injection temperature 260 ° C
  • the structure of the metal thin shell member 1 having the resin bonding member of the present invention comprises: a main portion of a metal thin shell member 10, a TPR adhesive layer 20 and at least one plastic bonded member 40.
  • the metal thin shell member 10 is used as a 3C product including a common computer product such as a notebook computer, a communicator product such as a mobile phone or a consumer product, but is not limited to an outer casing. And including, without limitation, a metal thin-shell member formed by processing, such as press working, a metal substrate 11 having an appropriate thickness, such as an aluminum alloy substrate, the inner and outer substrate 11 of the metal substrate 11 being processed during a manufacturing process such as rolling Naturally produced by the precision relationship of the pressing surface (for the sake of clarity, several small concave holes 12 in the figure are enlarged), it is not the use of any special aqueous solution or any relevant process of immersing the metal substrate 10 in a special aqueous solution.
  • the outer surface 13 of the metal substrate 11 may be subjected to other processing to have a decorative outer cover 15 such as a plating layer, an anodized layer, a lacquer layer, a film layer or the like to increase the metal thin shell member 10 The external beauty.
  • a decorative outer cover 15 such as a plating layer, an anodized layer, a lacquer layer, a film layer or the like to increase the metal thin shell member 10 The external beauty.
  • the TPR adhesive layer 20 is disposed on the metal surface-like inner surface 12 of the metal thin shell member 10, or may be disposed only on the inner surface 12 to establish a portion of the plastic bonded member 40.
  • the portion of the TPR adhesive layer 20 is not limited, and is applied to the inner surface 12 by printing or spraying or by automatic dispensing equipment.
  • the plastic bonding member 40 is injection molded on the inner surface 12 of the metal thin shell member 10 by a plastic injection molding process.
  • the number, position and shape of the plastic bonding member 40 are not limited, and can be changed according to the needs of use, such as designing a socket. Different structures such as those shown in Figs. 6 and 7 or reinforcing ribs; and the plastic bonding members 40 are formed by injection of the existing pressure and temperature of 40a as shown in Fig. 5 to adhere to the TPR.
  • the layers 20 are integrated into one another, that is, the plastic bonding members 40 and the TPR adhesive layer 20 are mutually heat-fused, and at the same time, the partial thickness of the TPR adhesive layer 20 is forced to penetrate, for example, 10% (about 40-50 ⁇ ).
  • the plastic bond members 40 after the injection molding can be stably disposed on the metal shell member 10 in a metallic form.
  • the inner surface 12 of the surface is combined with the metal thin shell member 10 to form a firmly integrated integrated composite structure to achieve direct assembly of various components in the subsequent assembly operation on the plastic bonded members 40. Not peeling tight The degree of adhesion.
  • the injection material of the plastic bond member 40 includes and is not limited to one or a combination of the following groups: ABS (styrene resin), PC (polycarbonate resin) , Acrylic resin (acrylic resin / acrylic resin), Nylon (nylon / polyamide resin), etc.
  • ABS styrene resin
  • PC polycarbonate resin
  • Acrylic resin acrylic resin / acrylic resin
  • Nylon nylon / polyamide resin
  • the pressure and temperature at the time of injection molding of the above-mentioned injection materials ⁇ 40a> were as follows: the injection pressure of ABS was 80 kg/mm 2 , and the injection temperature was 200. C; PC injection pressure 120kg/mm 2 , injection temperature 260 ° C; Acrylic resin injection pressure 100kg / hidden 2 , injection temperature 240. C; and Nylon (nylon / polyamide resin) injection pressure 80kg / mm 2 , injection temperature 260 ° C 0
  • the metal substrate 11 is an aluminum alloy plate but the outer layer 30 is made of different materials
  • the structure of the composite board 1 of the present invention and the functions thereof can be further explained:
  • the metal thin shell member 1 having the resin joint member of the present embodiment comprises: a metal thin shell member 10 formed of an aluminum alloy substrate 11 having a thickness of 0.8 mm, and a decorative outer covering layer 15 on the outer surface thereof is a cloth layer.
  • the cloth layer is made of artificial nylon such as nylon, polyester fiber, acrylic fiber and the like and has a thickness of 0.3 mm;
  • the TPR adhesive layer 20 is a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin.
  • the thickness of the plastic bond member 40 includes, but is not limited to, a hollow cylindrical socket as shown in FIGS. 5-7, and the interior of the hollow cylindrical socket can be thermally melted into a metal (such as copper).
  • the kit is formed to form a metal socket for strong locking of the fastener; and the dimensions of the plastic coupling 40 are: length 262 mm, width 178 mm, thickness lmm, height 9.5 ⁇ ; as a result, it is found that the plastic of the embodiment
  • the peel strength of the bond is 5 kg per square centimeter
  • the environmental test adhesion is -40 ° C to 85 ° C and 85 ° C to - 40 ° C per minute heating or cooling 1 ° C and 4 Secondary cycle, wherein the plastic bond member (40) is thin with metal
  • the case member (aluminum alloy substrate) is not peeled off.
  • the metal thin shell member 1 having the resin bonding member of the embodiment comprises: a metal thin shell member 10 having a thickness of
  • the 0.8 mm aluminum alloy substrate 11 is composed of a decorative outer covering layer 15 of a PVC (vinyl chloride resin) synthetic rayon or PU (polyurethane) synthetic rayon, and the TPR adhesive layer 20 is embedded with styrene.
  • the segment copolymer is composed of a thermoplastic rubber film synthesized by a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ m; the plastic bond member 40 includes, but is not limited to, a hollow cylindrical socket for hot melt embedding into a metal sleeve to form a metal.
  • the size of the plastic bond member 40 is: 262 mm in length, 178 mm in width, 1 mm in thickness, and 9.5 mm in height; as a result, it is found that the peel strength of the plastic bond member 40 of the present embodiment is per square centimeter. 5 kg, environmental test adhesion is - 40 ° C to 85 ° C and 85 ° C to - 40 ° C per minute heating or cooling 1 ° C and 4 cycles, wherein the plastic bond (40) It does not peel off from the thin metal shell (aluminum alloy substrate).
  • the structure of the metal thin-shell member 1 having the resin bonding member of this embodiment is substantially the same as that of the embodiment 2, The same point is that the metal thin shell member 10 is formed by stamping an aluminum alloy substrate 11 having a thickness of 0.8 mm, and the outer covering layer 15 is formed by stamping and forming the aluminum alloy substrate 11 having the thickness of 0.8, and then sandblasting and The outer surface of the anode surface is colored.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Description

具有塑质结合件的金属薄壳件及其制法 技术领域
本发明有关一种具有塑质结合件的金属薄壳件及其制法， 尤指一种先在一金 属薄壳件的金属表面上贴合一 TPR 粘着层其由丁苯嵌段共聚物与碳氢石油树脂合 成的热塑性橡胶薄膜， 再利用射出成型工艺， 于该 TPR 粘着层上射出成型该等塑 质结合件， 使该等塑质结合件由射出成型时射出料的压力及温度以与该 TPR 粘着 层及金属薄壳件结合成形成一稳固结合的一体化复合式结构体。 背景技术
市面上各种产品尤其电子产品， 包含常见的电脑 （computer) 产品如笔记型 电脑 ( Notebook computer, 简称 NB ) 、 通讯 (communication) 产品如手机或消 费性（consumer)产品等 3C产品但不限制， 常应用一薄壳件作为产品的外壳使用； 该薄壳件随产品的设计要求而具有不同的结构， 而若以一薄壳件的基体 （base) 所使用的材质而言， 可概分为塑质薄壳件及金属薄壳件两主要结构类别。
具有外在装饰面的塑质薄壳件一般利用嵌入模具式装饰用制程 （ in- mold decorating process, 简称 IMD) 制成， 其将一形成三维空间成型形状且印刷有图 案的载体 （ substrate ) 如塑质膜， 以下简称 IMD膜 （ IMD Π lm ) , 嵌置于一成型 模具内， 再利用塑胶射出成型工艺使热熔树脂射出成型在该 IMD膜的背面以成型 该壳体的基体， 以下简称树脂基体 （ resin base) , 使该树脂基体与 IMD膜结合 构成——体式塑质薄壳件， 其中， 该 IMD 膜 （ IMD film) 可以固定结合方式设在 树脂基体 （ resin base) 的外表面上而形成一永久性装置物， 供作为该塑质薄壳 件的一外装饰面或一保护面或二者都是； 此外该 IMD膜也可以暂时固定方式设在 树脂基体 （ resin base) 的外表面上而形成一暂时性装置物， 完成后可将该 IMD 膜撕离， 并使该 IMD 膜上的印刷图案转印或留存在树脂基体的外表面上供作为该 塑质薄壳件的一外装饰面。
针对上述的塑质薄壳件结构设计及其制造方法， 目前存在很多先前技术， 包 含：
US3, 654, 062揭示一具有一压合式表面片 ( a laminated facing sheet ) 的模 制饰板 （a molded decorative plaque ) 的相关技术， 其将热熔塑胶射出成型在 一已具有模具构造的压合表面片的背面上而形成。 US6, 117, 384揭示利用一具有多 彩颜色的薄膜， 再将热熔树脂射出成型在该薄膜的背面而构成一永久结合的立体 物件的制程相关技术。 US4，391,954 揭示一包含芳香族碳酸盐聚合物 （aromatic carbonate polymer ) 与一由环己烷二曱醇 ( cyclohexanedimethanol ) 取得的多 元酷 (polyester) 的热塑性模制复合体 ( thermoplastic molding composition) 的相关技术。 US4， 125， 572揭示一包含芳香族碳酸盐聚合物 （ aromatic carbonate polymer )与一由——月旨肪族 ( aliphatic )或环月旨肪族 醇 ( eye loa 1 i pha t ic diol ) 取得的多元酯 （ polyester ) 的热塑性模制复合体 ( thermoplastic molding composition ) 的相关技术。 US6,465，102 揭示一包含一装饰用表面区域及一个一 体式形成的聚合基体 （polymeric base) 的物品及其模制方法， 且该聚合基体包 含透明的环脂肪族多元酯树脂 （ cycloaliphatic polyester resin ) , 其中该环 脂肪族多元酯树脂系不受芳香族部分 ( aromatic moiety ) 干扰的相关技术 （An article comprising a decorative surface area and an integral formed polymeric base comprising transparent cycloal iphat ic polyester res in, wherein the cycloal iphat ic polyester res in is free from an aromatic moiety and the method of molding thereof ) 。 US6， 117, 384 揭示一改良的嵌入模具式 装饰用制程 （ in- mold decorating process, IMD) 的相关技术。 US6, 136, 441 揭 示多层式塑质物品 （multilayer plastic articles ) 的相关技术。 参考上述各种 有关塑质壳体的结构设计或制造方法等先前技术的专利说明书内容， 可知该等先 前技术大都是将一塑质壳体所包含的塑质膜（即 IMD膜）及树脂基体（ resin base) 分别作出进一步的限定（ limitation) , 如将塑质膜（ IMD膜）或树脂基体（ res in base) 限定为某一特殊化学族塑质材料， 以制成一稳固结合不易剥离的一体式复 合塑质板材， 且又可与其他专利 （先前技术）之间有区别性。
然而， 当一由复合材构成的塑质薄壳件物品的塑质膜 （即 IMD膜）及 /或树脂 基体 （ resin base) 被分别特殊化限定时， 不但使所使用的材料受到限制， 也使 塑质膜 （即 IMD膜）及 /或树脂基体 （ resin base) 的应用相对受到限制， 不利于 所制成的塑质薄壳件的应用， 例如为多样化需要而欲选用包含但不限制布面、 皮 革面、 树脂纤维面等材料来作为塑质膜时， 则往往无法利用相同的技术或设备并 达成生产效率高、 可量产化且品质控管佳的功效， 相对无法提升该塑质外壳的使 用效率及应用范围， 因此可视为上述该等塑质薄壳件的缺点。
此外， 较常见的金属薄壳件包含： 以金属薄板如铝合金薄板由机械加工制成 的薄壳件形状物， 或进一步在该金属薄壳件形状物的外表面上另作表面加工处理 以呈现光泽或图棄， 或进一步在该金属薄壳件形状物的外表面上另再设置一树脂 层如树脂薄膜用以保护金属外表面以避免使用中受到刮、 碰等损伤， 或进一步在 该金属薄壳件形状物的外表面上另设置一层具有图案的树脂层， 用以保护金属外 表面并增进产品的外观美感或触感， 或随产品的内部组件的组装需要而利用塑胶 射出成型技术或注塑粘合固着方式 （只指通过注塑成型的成型方式） 直接在该金 属薄壳件形状物的内表面 （金属面） 上适位处设置或粘合固着各种组装用塑质结 合件如凸缘形状物或肋板形状物等， 用以简化该等组装用塑质结合件的结构及整 体厚度， 并增进结构强度。
针对上述的金属薄壳件的结构设计及其制造方法， 目前已存在很多先前技术， 包含： 美国发明专利 US5，695，699 , US5, 472, 782 及美国发明专利公开案 US2009/011740K US2008/0127479, US2007/0218721等， 兹以下列专利分别说明: 中国发明专利申请号 ZL02805359.1 (国际申请 PCT / JP2002/007267, 国际 公布 WO2003/064150 ) 揭示一种铝合金与树脂的复合体及其制造方法的相关技术， 其特征在于， 包括： 经过接触工序的铝合金形状物， 所述的接触工序是使铝合金 形状物与溶解选自氨、 肼 （联胺） 、 甲基胺及乙二胺中的一种以上的化合物的水 溶液接触， 使上述水溶液吸附、 残留在其表面的工序， 和通过注塑成型一体地附 着在前述铝合金形状物的树脂， 所述树脂选自聚对苯二曱酸亚烷基酯、 以前述聚 对苯二曱酸亚烷基酯为主体的共聚物、 和含有前述聚对苯二曱酸亚烷基酯成分的 热塑性组合物中的一种以上。
中国发明专利申请号 ZL200380102886.0 (国际申请 PCT/JP2003/014213, 国 际公布 WO2004/041532 ) 揭示一种铝合金与树脂的复合体及其制造方法的相关技 术， 其特征在于， 由经过选自氨、 肼 （联胺） 和水溶性胺化合物一种以上的水溶 液中浸渍的浸渍工序的铝合金形状物和一体地附着在所述铝合金形状物的表面 上， 合有聚苯硫醚成分的热塑性组合物构成。
中国发明专利申请号 ZL200380104500.X (国际申请 PCT/JP2003/014214, 国 际公布 WO2004/041533 ) 揭示一种铝合金与树脂的复合体及其制造方法的相关技 术， 其特征在于， 由表面粗糙度为 5μπι~ 50μηι且其表面具有 Ιμπι以下的微细凹部 或凸部的铝合金形状物， 与浸入所述凹部或凸部而固定， 纵横平均线膨胀系数为 2 - 4xlO"5oC-l 的以聚对苯二甲酸丁二醇酯树脂或聚苯硫醚为主要成分的热塑性组 合物构成。
中国发明专利申请号 ZL200680046075.7 (国际申请 PCT/ JP2006/324493, 国 际公布 WO2 GG7/066742 )揭示一种金属树脂复合体及其制造方法的相关技术， 其特 征在于， 由铝合金构件和热塑性合成树脂组合物构件形成， 所述铝合金构件是如 下构件： 经过浸渍于选自氨、 肼 （联胺） 和水溶性胺化合物的一种以上的水溶液 的工序， 用电子显微镜观察， 其表面被数均内径为 10 ~ 80nm的凹部覆盖， 所述热 塑性合成树脂组合物构件是如下构件： 经注塑成型而固着于所述铝合金构件的所 述表面上， 并且树脂成分组成中的主要成分为聚酰胺树脂、 次要成分为耐冲击性 改良材料。
然，上述中国发明专利 ZL02805359. 1、 ZL200380102886. 0、 ZL200380104500. X 及 ZL200680046075. 7都揭示金属与树脂的复合体及其制造方法的相关技术， 而其 各别特征都在于， 该金属 （如铝合金） 形状物经过特殊选择的水溶液 （如水溶性 胺化合物一种以上的水溶液） 中浸渍的浸渍工序， 而再以具特殊选择成分的热塑 性树脂并以注塑成型方式一体地附着在该铝合金形状物的表面上而构成， 换言的， 该复合体中金属 （铝合金） 形状物的表面处理工序及树脂形状物的成分均被特殊 化限定， 且相对地较为复杂， 使复合体的制程及应用受到限制， 不利于该金属薄 壳件的使用效率及应用范围， 尤其使用特殊选择的水溶液更不符合目前的环保要 求， 因此上述金属薄壳件物品及其制法至少有下列缺点： 如须在注塑成型模具中 配合各树脂结合件而分别设计单一灌注口以进行高压定点注塑该树脂结合件， 导 致该金属薄壳件在注塑成型过程中因受高压而容易变形损坏， 而且增加制作该注 塑成型模具的困难度； 又由于金属薄壳件的金属表面须先以特殊水溶液进行浸渍 工序， 导致制程较为繁复， 不利于该金属薄壳件的量产化， 尤其该特殊水溶液更 有环保问题。
另如国内发明专利申请号 85100575 (公告号 404888 ) "具有优异加工密接性 的高鲜映性树脂被覆金属板" 揭示一种树脂被覆金属板的相关技术， 其以金属板 为基板，至少在该基板的片面上，由基板侧依序层合有涂料层、聚丙浠共聚物 100 ~ 20重量份和聚丙浠 100 ~ 0重量份构成的 5 ~ Ι ΟΟμπι厚的变性丙烯树脂层、花样或 / 及全面印刷层、 接着剂层、 5 ~ 100μιη厚的聚酯系树脂薄膜 （见其权利要求 1 ) ； 或由基板侧依序层合有涂料层、 花样或 /及全面印刷层、 聚丙烯共聚物 100 - 20重 量份和聚丙烯 100 ~ 0重量份构成的 5 ~ Ι ΟΟμηι厚的变性丙烯树脂层、接着剂层、 5 ~ Ι ΟΟμπι厚的聚酯系树脂薄膜 （见其权利要求 2 ) ； 或由基板侧依序层合有涂料层、 聚丙烯共聚物 100 ~ 20重量份和聚丙烯 100 - 0重量份构成的 5 ~ Ι ΟΟμπι厚的变性 丙烯树脂层、 接着剂层、 5 - Ι ΟΟμπι厚的透明聚酯系树脂薄膜（见其权利要求 3 ) ； 或由基板侧依序层合有涂料层、 5 ~ Ι ΟΟμπι厚的变性烯烃层、 接着剂层、 5 ~ 100μπι 厚的透明聚酯系树脂薄膜（权利要求 4 ) 。 然， 本案结构中由基板侧依序层合的树 脂被覆层的成分均已被特殊化限定， 且主要目的为该树脂被覆金属板具有高鲜映 性， 相对使该金属板的外形受到限制， 不利于所制成的金属薄壳件的应用。
再如中国台湾发明专利申请号 86106332 (公告号 434145 ) "具备较高清晰反 射性及优良工作粘着性的涂覆树脂金属片" 揭示一种涂覆树脂金属片的相关技术， 其包括： 作为底层片的金属片， 其粗糙度的算术平均值偏差幅度（Ra )数值介于 0 微米及 10微米之间； 透明软树脂层， 其包括未硬化的混合型态树脂层， 聚酯树脂 的涂料涂覆层， 或聚烯烃树脂； 包括颜料的接着层； 具有两面经过光泽处理的透 明树脂薄膜， 其中至少一金属片表面被着色层， 软树脂层， 接着层和透明层覆盖， 各层从金属片侧到透明树脂薄膜依序覆盖。 然， 本案结构中由金属片侧依序层合 的树脂被覆层的成分均已被特殊化限定， 且主要目的该树脂被覆金属板具有高鲜 映性， 相对该金属板的外形受到限制， 不利于所制成的金属薄壳件的应用。
再如中国台湾发明专利申请号 093119015 (证书号 1280190 ) "电子装置壳体 金属板成型方法及其结构" ， 其针对前述的发明专利申请号 86106332 (公告号 434145 )及发明专利申请号 85100575 (公告号 404888 ) 加以改进， 其揭示一种设 置皮膜层的铝合金基板的相关技术， 其方法至少包括： 一 "涂布接着剂" 步骤， 于一由铝合金所制成的金属基板的至少一侧表面涂布一层接着剂， 且该接着剂具 有金属粉末； 一 "烘烤加热" 步骤， 加热该涂布接着剂的金属基板， 使该接着剂 适当软化； 一 "滚压，， 步骤， 由加热的滚轮将一皮膜层滚压层合于该接着剂上， 其中该皮膜层由至少一聚氯乙烯层、 一接着层、 一聚酯层依序层迭结合而成， 且 接着层具有金属粉末； 一 "冷却成型" 步骤， 使该皮膜层与金属基板得以密着结 合。 然， 本案结构中由铝合金金属基板一侧表面所层合的皮膜层的成分由至少一 聚氯乙烯层、 一接着层、 一聚酯层依序层迭结合而成， 因此该皮膜层已被特殊化 限定， 相对使该金属基板所呈现的外形受到限制， 不利于所制成的金属薄壳件的 应用。
再如中国台湾实用新 ^专利申请号 093210282 (证书号 M261368 ) "电子装置 壳体金属板结构" 前述发明专利申请号 093119015 (证书号 1280190 ) 中结构的新 型专利案。 然， 本案结构即存在如同其发明专利申请号 093119015 的皮膜层已被 特殊化限定的缺点。
再如中国台湾实用新型专利申请号 097208521 (证书号 M345706 ) "复合金属 板结构" 揭示一包括一金属基板、 一复合树脂胶层涂覆于该金属基板并加热软化、 及一金属面板以一辊轮滚压层合于该复合树脂胶层上而使该金属面板与金属基板 密着结合。 然， 本案结构的二外側面一为金属面板一为金属基板， 故存在二外侧 面已被特殊化限定的缺点。
再如中国台湾实用新型专利申请号 096215339 (证书号 M328384 ) "环保型贴 皮金属结构" 揭示一贴皮金属结构的相关技术， 其至少包括： 一金属基板； 一接 着剂层涂布于前述金属基板的至少一侧表面并加热使的适当软化； 及一皮膜层由 一聚氨酯底层及聚氨酯面层依序层迭结合而成， 以一滚轮滚压层合于前述接着剂 层上然后冷却， 使该皮膜层与金属基板密着结合。 然， 本案结构中的皮膜层的成 分由由一聚氨酯底层及聚氨酯面层依序层迭结合而成， 因此该皮膜层已被特殊化 界定， 使该金属基板所呈现的外形或触感相对受到限制， 不利于所制成的金属薄 壳件的应用。
综上所述， 各种复合板材的先前技术确实都存在一些缺点， 本发明是针对上 述先 前技术 中 的 中 国 发 明 专 利 ZL02805359. 1 、 ZL200380102886. 0 、 ZL200380104500. X及 ZL200680046075. 7等所揭示各种金属与树脂的复合体及其制 法的相关技术的缺点， 加以有效解决。 发明内容
本发明的目的提供一种具有塑质结合件的金属薄壳件及其制法， 其在一金属 薄壳件的金属表面上或其中欲设立塑质结合件的局部处，设置一层厚度约 400-500 μπι的 TPR粘着层， 设置方式不限如以印刷或喷涂方式涂布， 该 TPR由丁苯嵌段共 聚物与碳氢石油树脂合成的热塑性橡胶薄膜； 再将该已具有 TPR 粘着层的金属薄 壳件置入并固定在一与该金属薄壳件的形状对应配合的射出成型模具的模穴内； 再利用塑料射出成型工艺， 于该金属薄壳件的金属表面的 TPR 粘着层上射出成型 该等塑质结合件，使该等塑质结合件由射出成型时射出料的压力及温度以与该 TPR 粘着层热熔结合成一体， 并同时迫使该 TPR粘着层的部分厚度如约 10% (约 40-50 μπι ) 得渗透至该金属薄壳件的金属表面上既有的细凹孔中， 使该等塑质结合件能 稳固设在金属薄壳件的金属表面上， 以结合形成一稳固结合的一体化复合式结构 体， 以有效地简化在金属薄壳件上设置塑盾结合件的制程及成型模具的制作， 并 可避免先前技术在制程及成型模具方面的诸多缺点如须以高压定点注塑方式成型 该树脂结合件以致模穴中的金属薄壳件容易受高压而变形， 且该金属表面须先以 特殊水溶液进行浸渍工序以致制程较为繁复且更有环保问题， 以及树脂结合件的 材料相对受限等缺点。
本发明再一目的在于提供一种具有塑质结合件的金属薄壳件及其制法， 其中 该等塑质结合件的射出成型工序利用一般塑料射出成型工艺达成， 且射出料采用 一般射出成型的压力及温度， 因此不但有利于射出成型模具的制作如可有效简化 射出料流道的安排及设计， 且该金属薄壳件的另一表面所具有装饰用外覆层如电 镀层、 阳极处理层、 烤漆层、 皮膜层等也不致在射出成型工序中因受压而变形或 损坏， 达成生产效率高、 容易量产化、 降低成本且成型品质容易控管的实用效果。
一种具有塑质结合件的金属薄壳件， 包含： 一金属薄壳件、 一 TPR 粘着层及 至少一塑质结合件， 其中： 该金属薄壳件， 以一具适当厚度的金属基板所加工成 金属基板在制作过程中于表层面上所自然产生的； 该 TPR 粘着层以丁苯嵌段共聚 物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 其厚度为 4 00-500 μπι , 其设置 在该金属薄壳件的金属质内表面上； 该塑质结合件， 利用塑料射出成型工艺， 使 设有该 TPR 粘着层的金属薄壳件置入并固定在射出成型模具的模穴中， 以使射出 料射出成型于该金属薄壳件的内表面上而构成； 其中， 该塑质结合件由射出成型 时射出料的射出压力及温度， 以与该 TPR 粘着层相互热熔结合成一体， 并同时迫 使该 TPR 粘着层的部分厚度得渗透至该金属薄壳件的金属质内表面上的数个细凹 孔中， 使射出成型后的该塑质结合件与金属薄壳件结合形成一体化复合式结构体。
一种具有塑质结合件的金属薄壳件的制法， 用以制造具有塑质结合件的金属 薄壳件， 包含下列步骤： 提供一金属薄壳件， 其以一具适当厚度的金属基板所加 工成型， 且该金属基板的内、 外表面的表层面具有近乎均勾散布的数个细 EJ孔； 于该金属薄壳件的呈金属质的内表面上设置一层厚度 4 00-5 00 μπι的 TPR粘着层， 该 TPR 粘着层由丁苯嵌段共聚物与碳氢石油树脂合成的热塑性橡胶薄膜； 再利用 塑料射出成型工艺， 使设有该 TPR 粘着层的金属薄壳件固定在一射出成型模具的 模穴中， 以使射出料于该金属薄壳件的内表面上并在该 TPR 粘着层上射出成型至 少一塑质结合件， 且该塑质结合件由射出成型时射出料的压力及温度以与该 TPR 粘着层结合成一体， 并同时迫使该 TPR 粘着层的部分厚度得渗透至该金属薄壳件 的金属质内表面上的数个细凹孔中， 使射出成型的该塑质结合件与金属薄壳件结 合形成一体化复合式结构体； 待冷却后， 由射出成型模具取出， 即完成一具有塑 质结合件的金属薄壳件。 本发明能够简化该等塑质结合件的结构及增进结构强度， 并避免先前技术的 缺点， 达成制程及成型模具相对简化的目的， 生产效率高、 容易量产化、 降低成 本且成型品质容易控管。
为使审查员能进一步了解本发明的详细结构及作用功效， 兹配合图示说明于 后。 附图说明
图 1为本发明具有树脂结合件的金属薄壳件的制法流程示意图；
图 2为本发明的金属薄壳件一实施例的前视立体示意图；
图 3为图 2的背视立体示意图；
图 4为图 2所示金属薄壳件的断面 （局部放大） 示意图；
图 5 为本发明的射出成型模具的断面示意图， 其中树脂结合件通过射出成型 固设在金属薄壳件的金属表面上；
图 6为本发明具有树脂结合件的金属薄壳件的断面 （局部放大） 图； 图 7 为本发明的具有树脂结合件的金属薄壳件一实施例的立体 （背视） 示意 图。
附图标记说明
具有塑质结合件的金属薄壳件 1; 金属薄壳件 10; 金属基板 11; 内表面 12; 局部处 12a; 外表面 13; 细凹孔 14; 外覆层 15; TPR粘着层 20; 射出成型模具 30; 模穴 31; 上模具 32; 下模具 33; 模穴面 34; 灌注口 35; 射出料流道 36; 成型模 穴 37; 塑质结合件 40。 具体实施方式
参考图 1, 其本发明的制法流程示意图。 本发明的具有塑质结合件的金属薄壳 件 1的制法， 主要包含以下步骤：
提供一金属薄壳件 10; 本发明的金属薄壳件 10 通指一般产品如常见的电脑 ( computer ) 产品 ίί口笔 i己型电脑 ( Notebook computer ) 、 通讯 (communication) 产品如手机或消费性 （consumer) 产品等 3C产品但不限制的外壳体， 在此以一笔 记型电脑的外壳体如图 2、 3、 4所示为例说明； 该金属薄壳件 10包含且不限制以 一具适当厚度的金属基板 11 如铝合金基板经加工如冲压加工所构成的金属薄壳 件， 该金属基板 11具有一内表面 I2及一外表面 13， 且该内、 外表面 I2、 13的表 基板 1 1在制作过程如辗压过程中因辗压面的精密度关系而自然产生的； 又该金属 基板 1 1的外表面 1 3可经过其他的加工处理而具有装饰用外覆层 15如电镀层、 阳 极处理层、 烤漆层、 皮膜层等， 以增加该外表面 1 3的外在美观性；
再于该金属薄壳件 10的呈金属表面样态的内表面 12上或其中欲设立塑质结 合件的局部处 12a , 设置一层厚度约 400- 500 μηι的 TPR粘着层 20; 该 TPR粘着层 20由丁苯嵌段共聚物与碳氢石油树脂合成的热塑性橡胶薄膜，该 TPR粘着层 20的 设置方式不限制， 如以印刷方式或喷涂或以自动点胶涂布设备方式完成；
再将该已具有 TPR粘着层 20的金属薄壳件 10置入并固定在一射出成型模具 30的模穴 31 中如图 5所示； 该射出成型模具 30依据塑料射出成型工艺的既有技 术而设计， 其结构型态如模穴数目、 灌注口位置、 射出料流道或定位装置的安排 等不限制， 在此以图 5所示的一般射出成型模具 30为例说明， 该射出成型模具 30 可包含一上模具 32及一下模具 33但不限制， 其中该下模具 33的模穴 31 内设有 一与该金属薄壳件 1 0的形状对应配合的模穴面 34供安置并固定该金属薄壳件 10; 该上模具 32设有射出成型所需的灌注口 35、 射出料流道 36及欲设的各塑质结合 件 40的成型模穴 37等， 其中该灌注口 35、 射出料流道 36的安排不限制， 又该成 型模穴 37的设立数目、 位置及形状等不限制， 可随使用需要而变化设计， 也就是 本发明的塑质结合件 40的设立数目、 位置及形状等不限制并不限制， 可设计为承 座、 加强肋等不同结构， 在此， 该塑质结合件 40以一中空柱形承接座为例说明如 图 5-7 所示， 而该中空柱形承接座的内部一般再热熔嵌入一金属 （如铜） 套件以 形成一金属质承接座供锁固件强力锁固使用；
再利用塑料射出成型工艺， 于该金属薄壳件 10的内表面 12上并在该 TPR粘 着层 20上射出成型该等塑质结合件 40; 而该等塑质结合件 40即可由射出成型时 射出料 40a的既有的压力及温度， 与该 TPR粘着层 20热熔结合成一体， 并同时迫 使该 TPR粘着层 20的部分厚度如 1 0% (约 40-50 μπι ) 得渗透至该金属薄壳件 1 0 的金属质内表面 12上既有的数个细凹孔 14 中， 使射出成型的该等塑质结合件 40 能稳固设在金属薄壳件 1 0的内表面 12上， 以与金属薄壳件 10结合形成一稳固结 合的一体化复合式结构体， 即成为本发明具有塑质结合件 40的金属薄壳件 1 ;
待冷却后， 由射出成型模具 30取出， 即完成一具有塑质结合件的金属薄壳件 1的一体化复合式结构体如图 6、 7所示。
本发明的上述制法， 由于该 TPR粘着层 20可在射出成型过程中渗透至该金属 薄壳件 10的金属质内表面 12上既有的数个细凹孔 14中，并同时与塑质结合件 40 稳固地热融密着结合成一体， 故所制成具有塑质结合件的金属薄壳件 1 的金属薄 壳件 10与塑质结合件 40之间得能保持相当良好的密着性结合关系， 在经实体试 验后， 证明成型在内表面 12上的各塑质结合件 40均具有足够的抗剥离性， 足以 承受后续组装作业中各种不同组件施加在相对应配合的塑质结合件 40 上的结合 力， 如利用自动化设备将不同组件以螺丝固定在塑质结合件 40上； 由此， 该等塑 质结合件 40具有足够的结构强度， 并可避免如前述的先前技术的诸多缺点， 达成 制程及成型模具相对简化的目的。
尤其， 本发明与前述的该等先前技术相较， 本发明的制法更能符合目前的环 保要求。 本发明的制法利用该金属薄壳件 10即金属基板 11 如铝合金基板的内表 凹孔 14,以使该 TPR粘着层 20的部分厚度可在射出成型过程中直接渗入该等细凹 孔 14 中， 故本发明的制程可避免前述的 ZL02805359.1、 ZL200380102886.0、 ZL200380104500. X及 ZL200680046075.7等先前技术须准备特殊的水溶液并须将金 属基板先浸渍在该特殊水溶液等相关工序及再以具特殊成分的热塑性树脂成型并 粘着在该金属基板的表面上所造成的繁复制程及环保问题。
上述制程中， 在该金属薄壳件 10即金属基板 11如铝合金基板的内表面 12设 置一 TPR粘着层 20的前， 可针对该内表面 12的表面状态需要， 而先采取一净化 处理步骤， 该净化处理步骤包含且不限制为脱脂、 强力刷洗等， 主要目的在于使 该内表面 12的工作表面保持在一定程度的洁净状态， 以避免对后续设置该 TPR粘 着层 20的作业程序产生不良影响， 以使该 TPR粘着层 20与该内表面 12之间达到 良好的紧密接着效果。
上述制程中， 当利用塑料射出成型工艺以于该金属薄壳件 10的内表面 12上 并在该 TPR粘着层 20上射出成型该等塑质结合件 40时， 该等塑质结合件 40可选 择利用 ABS(苯乙烯树脂）、 PC(聚碳酸酯， Polycarbonate resin )、 Acrylic resin (压克力树脂 /丙烯酸树脂） 、 Nylon (尼龙 /聚酰胺树脂） 等但不限制以作为射出 成型时射出料 40a,而该等射出料 40a及其在射出成型时的既有的压力及温度分别 为： ABS的射出压力 80kg/mm2， 射出温度 200° C; PC的射出压力 120kg/mm2 , 射 出温度 260° C; Acrylic res in的射出压力 100kg/mm2 ,射出温度 240° C;及 Nylon (尼龙 /聚酰胺树脂） 的射出压力 80kg/隱 2 ， 射出温度 260° C„
参考图 6、 7, 其分别为本发明具有树脂结合件的金属薄壳件一实施例的结构 剖面及立体 （背视） 示意图。 本发明具有树脂结合件的金属薄壳件 1 的结构依序 包含： 一金属薄壳件 10、 一 TPR粘着层 20及至少一塑质结合件 40等主要部分。
该金属薄壳件 10 用以作为包含常见的电脑 （computer ) 产品如笔记型电脑 ( Notebook computer )、 通讯 ( communicat ion )产品如手机或消费性 ( consumer ) 产品等 3C 产品但不限制的外壳体， 包含且不限制以一具适当厚度的金属基板 11 如铝合金基板经加工如冲压加工所构成的金属薄壳件， 该金属基板 11的内、 外表 属基板 11在制作过程如辗压过程中因辗压面的精密度关系而自然产生的 （为求明 显， 图中的数个细凹孔 12放大表示） ， 并非是利用任何经过特殊水溶液或任何将 金属基板 10浸渍在特殊水溶液的相关工序而形成者； 又该金属基板 11 的外表面 13可经过其他的加工处理而具有装饰用外覆层 15如电镀层、阳极处理层、烤漆层、 皮膜层等， 以增加该金属薄壳件 10的外在美观性。
该 TPR粘着层 20以丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜 构成， 其材料成分的比例可为不同如 TPU、 TPE薄膜， 其厚度约 400-500 μπι ( 1μπι= l(T6m) 。 该 TPR粘着层 20设置在该金属薄壳件 10的呈金属表面样态的内表面 12 上， 也可只设置在该内表面 12上欲设立塑质结合件 40的局部处 12a; 该 TPR粘着 层 20的设置方式不限制， 如以印刷方式或喷涂方式或自动点胶涂布设备方式完成 以涂布在内表面 12上。
该塑质结合件 40利用塑料射出成型工艺而射出成型于该金属薄壳件 10的内 表面 12上， 其设立数目、 位置及形状不限制， 可随使用需要而变化设计， 如设计 为承接座如图 6、 7所示或加强肋等不同结构； 又该等塑质结合件 40 由射出成型 时射出料 〈如图 5所示的 40a〉 的既有的压力及温度， 以与该 TPR粘着层 20结合 成一体， 即该等塑质结合件 40与 TPR粘着层 20之间已相互热熔结合， 并同时迫 使该 TPR粘着层 20的部分厚度如 10% (约 40-50 μηι ) 得渗透至该金属薄壳件 10 的金属质内表面 12上既有的数个细凹孔 14 中， 使射出成型后的该等塑质结合件 40能稳固设在金属薄壳件 10的呈金属质面的内表面 12上，以与金属薄壳件 10结 合形成一稳固结合的一体化复合式结构体， 以达成容许后续组装作业中各种不同 组件直接组装在该等塑质结合件 40上而不剥离的紧密粘着程度。
该塑质结合件 40的射出料 〈如图 5所示的 40a〉 包含且不限制为下列组群中 的一种或其组合： ABS (苯乙烯树脂） 、 PC (聚碳酸酯， Polycarbonate resin) 、 Acrylic resin (压克力树脂 /丙烯酸树脂） 、 Nylon (尼龙 /聚酰胺树脂） 等， 而 该等射出料〈 40a〉在射出成型时的压力及温度分别为： ABS的射出压力 80kg/mm2 , 射出温度 200。 C; PC的射出压力 120kg/mm2， 射出温度 260° C; Acrylic resin 的射出压力 100kg/隱 2 , 射出温度 240。 C; 及 Nylon (尼龙 /聚酰胺树脂） 的射出 压力 80kg/mm2， 射出温度 260° C0
兹由以下各实施例， 其中金属基板 11都为铝合金板但外饰层 30为不同材质， 进一步说明本发明复合板材 1的结构及其所能达成的作用功效：
<实施例 1 >
本实施例具有树脂结合件的金属薄壳件 1 包含： 一金属薄壳件 10为以厚度为 0.8mm的铝合金基板 11构成， 其外表面的装饰用外覆层 15为一布料层， 该布料层 以人造歼维如尼龙、 聚脂纤维、 压克力纤维等所构成且厚度为 0.3mm; 该 TPR粘着 层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μιη; 该塑质结合件 40 包含但不限制一中空柱形承接座如图 5-7所示， 而 该中空柱形承接座的内部可热熔嵌入一金属 （如铜） 套件以形成一金属质承接座 供锁固件强力锁固使用； 而该等塑质结合件 40的尺寸为：长度 262mm、宽度 178mm、 厚度 lmm、 高度 9.5匪； 结果发现， 本实施例的塑质结合件的剥离强度密着性为每 平方公分 5公斤， 环境测试密着性为由 - 40°C至 85°C以及 85°C至 - 40°C每分钟升温 或降温 1°C且经 4次循环， 其中该塑质结合件 （40 ) 与金属薄壳件 （铝合金基板） 不剥离。
<实施例 2 >
本实施例具有树脂结合件的金属薄壳件 1包含： 一金属薄壳件 10为以厚度为
0.8mm的铝合金基板 11构成， 其外表面的装饰用外覆层 15为 PVC (氯乙烯树脂 ) 合成人造纤维或 PU (聚氨酯， Polyurethane )合成人造纤维， 该 TPR粘着层 20为 由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μπι; 该塑质结合件 40 包含但不限制一中空柱形承接座供可热熔嵌入一金 属套件以形成一金属质承接座， 而该等塑质结合件 40的尺寸为： 长度 262mm、 宽 度 178mm、 厚度 lmm、 高度 9.5mm; 结果发现， 本实施例的塑质结合件 40的剥离强 度密着性为每平方公分 5公斤， 环境测试密着性为由 - 40°C至 85°C以及 85°C至 -40 °C每分钟升温或降温 1°C且经 4次循环，其中该塑质结合件（ 40 )与金属薄壳件（铝 合金基板） 不剥离。
<实施例 3〉
本实施例具有树脂结合件的金属薄壳件 1 的结构大体上与实施例 2相同， 不 同点在于该金属薄壳件 10为以厚度为 0.8mm的铝合金基板 11 经铝板沖压成型构 成， 且外覆层 15为该 0.8麵厚度的铝合金基板 11经冲压成型后， 再以喷砂及阳 极表面上色处理的外覆层。
以上对本发明的描述是说明性的， 而非限制性的， 本专业技术人员理解， 在 权利要求限定的精神与范围之内可对其进行许多修改、 变化或等效， 但是它们都 将落入本发明的保护范围内。

Claims

权利要求
1、 一种具有塑质结合件的金属薄壳件， 其特征在于， 包含： 一金属薄壳件、 一 TPR粘着层及至少一塑质结合件， 其中：
该金属薄壳件， 以一具适当厚度的金属基板所加工成型， 且该金属基板的内、 外表面的表层面具有近乎均勾散布的数个细凹孔其为该金属基板在制作过程中于 表层面上所自然产生的；
该 TPR 粘着层以丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构 成， 其厚度为 400- 500 μιη, 其设置在该金属薄壳件的金属质内表面上；
该塑质结合件， 利用塑料射出成型工艺， 使设有该 TPR 粘着层的金属薄壳件 置入并固定在射出成型模具的模穴中， 以使射出料射出成型于该金属薄壳件的内 表面上而构成；
其中， 该塑质结合件由射出成型时射出料的射出压力及温度， 以与该 TPR 粘 着层相互热熔结合成一体， 并同时迫使该 TPR 粘着层的部分厚度得渗透至该金属 薄壳件的金属质内表面上的数个细凹孔中， 使射出成型后的该塑质结合件与金属 薄壳件结合形成一体化复合式结构体。
2、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该金属 基板为一铝合金板。
3、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该 TPR 粘着层设置在该金属薄壳件的金属貭的内表面上或其中欲设立塑质结合件的表面 局部处。
4、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该 TPR 粘着层的设置方式包含印刷方式及喷涂方式。
5、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该 TPR 粘着层的厚度 400-500 μπι中的 1 0%部分厚度 40-50 μπι在射出成型该塑质结合件时 渗透至该金属薄壳件的金属质内表面上的数个细凹孔中。
6、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该塑质 结合件的射出料包含下列组群中的一种或其组合： ABS、 PC、 Ac ry l i c res i n . Ny l on.
7、 如权利要求 1所述的具有塑质结合件的金属薄壳件， 其特征在于， 该金属 基板的外表面设具一外覆层其由加工处理形成。
8、 如权利要求 7所述的具有塑质结合件的金属薄壳件， 其特征在于， 该外覆 层包含下列组群中的一种： 电镀层、 阳极处理层、 烤漆层及皮膜层。
9、 一种具有塑质结合件的金属薄壳件的制法， 其特征在于， 用以制造如权利 要求 1至 8任一项所述的具有塑质结合件的金属薄壳件， 包含下列步骤:'
提供一金属薄壳件， 其以一真适当厚度的金属基板所加工成型， 且该金属基 板的内、 外表面的表层面具有近乎均匀散布的数个细凹孔；
于该金属薄壳件的呈金属质的内表面上设置一层厚度 400-500 μπι的 TPR粘着 层， 该 TPR粘着层由丁苯嵌段共聚物与碳氢石油树脂合成的热塑性橡胶薄膜； 再利用塑料射出成型工艺， 使设有该 TPR 粘着层的金属薄壳件固定在一射出 成型模具的模穴中， 以使射出料于该金属薄壳件的内表面上并在该 TPR 粘着层上 射出成型至少一塑质结合件， 且该塑质结合件由射出成型时射出料的压力及温度 以与该 TPR粘着层结合成一体， 并同时迫使该 TPR粘着层的部分厚度得渗透至该 金属薄壳件的金属质内表面上的数个细凹孔中， 使射出成型的该塑质结合件与金 属薄壳件结合形成一体化复合式结构体；
待冷却后， 由射出成型模具取出， 即完成一具有塑质结合件的金属薄壳件。
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