WO2018036270A1 - 热塑性复合材料产品及其制作方法 - Google Patents

热塑性复合材料产品及其制作方法 Download PDF

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Publication number
WO2018036270A1
WO2018036270A1 PCT/CN2017/090865 CN2017090865W WO2018036270A1 WO 2018036270 A1 WO2018036270 A1 WO 2018036270A1 CN 2017090865 W CN2017090865 W CN 2017090865W WO 2018036270 A1 WO2018036270 A1 WO 2018036270A1
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Prior art keywords
thermoplastic composite
shot mold
sheet
infrared
product
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PCT/CN2017/090865
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English (en)
French (fr)
Inventor
郭雪梅
吴政道
朱明毅
吴秉谦
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汉达精密电子(昆山)有限公司
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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
    • 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
    • B29C45/1418—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 inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/12—Compression 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • 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
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0822—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • 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
    • B29L2031/3431—Telephones, Earphones
    • B29L2031/3437—Cellular phones
    • 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
    • B29L2031/3475—Displays, monitors, TV-sets, computer screens
    • 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
    • B29L2031/764—Photographic equipment or accessories

Definitions

  • the present disclosure pertains to the field of fabrication of composite products, for example, to a thermoplastic composite product and a method of making the same.
  • Thin and light products will form a thin shell of the outer casing or internal parts of the product, and require high strength and high rigidity while being thin and light.
  • Thermoplastic composite materials have the advantages of light weight, high specific strength and specific modulus, chemical resistance, fatigue resistance, and easy integral molding. They are widely used in the production of military, aircraft, wind power and other products. Due to the excellent mechanical properties of thermoplastic composite materials, it can also be widely used in the casings of electronic and electrical equipment and information equipment such as notebook computers, tablet computers, cellular phones, portable terminals or cameras, and has been used to make the outer casing thinner and lighter. Weight and so on.
  • the composite materials used in electronic products are mostly processed by a hot pressing die into a desired shape structure, and then embedded in a mold for injection molding:
  • the prepreg For thermosetting composite sheets, the prepreg should be laid up as required and placed in a hot pressing mold to be pressed and solidified into a desired shape, and then placed in a plastic mold for injection molding.
  • the disadvantage of this operation mode is that the prepreg is formed for about 30 minutes, the molding cycle is long, and the plate after hot pressing needs to be further processed by milling, and the final product realization requires hot pressing mold pressing and plastic mold injection molding.
  • the procedures and processes are complex, resulting in low efficiency and high cost.
  • thermoplastic composite sheet For the thermoplastic composite sheet, the sheet is cut and placed in a hot pressing mold to form a desired shape, and then placed in a plastic mold for injection molding.
  • the disadvantage of this operation mode is that the whole process of product realization requires two procedures of hot pressing mold pressing and plastic mold injection molding, and the process is complicated, resulting in low efficiency and high cost, and can not meet 3C (Computer Communication Consumer Electronic). Electronic) The need for mass production in the industry.
  • thermoplastic composite product which is combined with insert molding and two-shot molding, has a simple process and high efficiency, and is suitable for mass production.
  • thermoplastic composite product comprising:
  • the sheet being a sheet of thermoplastic composite material
  • the cut sheet is subjected to infrared heating
  • the infrared heated plate is placed in the first shot mold of the double shot mold for positioning;
  • the first shot mold is clamped to perform compression molding on the positioned sheet material, and the first plastic material is injection molded;
  • the second shot mold is opened to take out the product.
  • the sheet material is a thermoplastic composite sheet material containing carbon fibers, containing glass fibers or both carbon fibers and glass fibers.
  • the cut plate is subjected to infrared heating, comprising infrared heating of the cut plate by using an infrared oven, wherein the infrared oven has a temperature sensor and a plurality of sequentially arranged at the top and the bottom respectively.
  • infrared tubes and a removable hollow tray in the infrared oven are provided.
  • the cut sheet is subjected to infrared heating, including:
  • the infrared lamp heats the plate, and the temperature sensor detects whether the temperature is up to standard.
  • the cut sheet is subjected to infrared heating, and the infrared heating temperature is between the glass transition temperature and the melting temperature of the resin used in the thermoplastic composite sheet.
  • the first plastic material is a glass fiber reinforced composite material.
  • the injecting the first plastic material comprises: injection molding the first plastic material by a high-low temperature rapid prototyping method or a high-low temperature rapid prototyping and micro-foaming molding.
  • the second plastic material is a thermoplastic elastomer.
  • a water path is disposed in the first shot mold and the second shot mold of the two-shot mold, and steam or cooling water is introduced into the water path.
  • thermoplastic composite product A product produced by the method of producing a thermoplastic composite product according to any of the above.
  • the manufacturing method of the thermoplastic composite product of the present disclosure is combined with the insert into Type and double shot mode, that is, by heating the thermoplastic composite material sheet by infrared heating, heating and directly into the first shot mold of the double shot mold to form a 3D shape, and injection molding a hard rubber material to serve as a structural skeleton The function is then rotated into the second shot mold of the double shot mold to mold the soft rubber material to cushion shock absorption and waterproof.
  • the infrared heating rate can reach 5 ° C / s -20 ° C / s, and the heating rate is extremely fast, which can save a lot of Time, and the steam and cooling water heat and cool the two-shot mold.
  • the heating rate and temperature drop rate of the double-shot mold can reach 2°C/s-5°C/s during the molding process, which makes the molding time short and the efficiency high. 3C industry requirements for mass production.
  • thermoplastic composite product of the present embodiment is a flow chart showing the steps of a method for fabricating a thermoplastic composite product of the present embodiment.
  • thermoplastic composite material of the present embodiment is a schematic view showing the structure of infrared heating in the method for fabricating the thermoplastic composite material of the present embodiment.
  • thermoplastic composite product of the present embodiment is a schematic view showing the structure of a thermoplastic composite product of the present embodiment.
  • FIG. 1 is a flow chart showing the steps of the method for fabricating the thermoplastic composite material product of the embodiment
  • FIG. 2 is a diagram showing the infrared heating method for the method for manufacturing the thermoplastic composite material product of the embodiment.
  • FIG. 3 is a schematic view showing the structure of a thermoplastic composite product of the present embodiment.
  • the two-shot mold described in the method for manufacturing the thermoplastic composite material of the present embodiment has a first shot mold and a second shot mold, and the male molds of the first shot mold and the second shot mold are identical, and the master molds are different.
  • the male mold of the first shot mold will drive the product to rotate to the second shot mold, and cooperate with the master mold of the second shot mold; meanwhile, the male mold of the second shot mold will rotate to the first At the shot mold, it cooperates with the master mold of the first shot mold.
  • the manufacturing method of the thermoplastic composite material of the embodiment includes: S100-S600.
  • the sheet material 20 is cut according to the shape of the product, and the sheet material 20 may be a thermoplastic composite material sheet 20 mixed with carbon fiber, glass fiber or carbon fiber glass fiber.
  • the cut plate 20 is subjected to infrared heating, that is, the cut plate 20 is placed in the infrared oven 10 for rapid heating, and the power of the infrared heating is adjustable, and the top and bottom portions of the infrared oven 10 are A plurality of infrared light tubes 11 arranged in sequence are arranged, and the distance between the infrared light tubes 11 is adjustable, wherein the infrared light tube 11 uses the same infrared wavelength as the thermoplastic composite material, which can improve the heating efficiency and the infrared
  • the top and bottom of the oven 10 are also respectively provided with a temperature sensor 12 for sensing whether the temperature is up to standard.
  • the specific steps of infrared heating the cut sheet 20 are: placing the cut sheet 20 on the hollow tray 13, and sliding the tray 13 into the infrared oven; the infrared tube 11 heating the sheet 20, the temperature sensor 12 Check if the temperature is up to standard.
  • the temperature rise rate of the infrared heating is 5 ° C / s (Celsius / sec) -20 ° C / s, the temperature of the surface of the sheet 10 can be rapidly raised to between the glass transition temperature and the melting temperature of the resin used in the thermoplastic composite sheet 10 At this time, the sheet 20 becomes soft, but no molten liquid is dropped.
  • the infrared-heated sheet 20 is placed in the first shot mold of the two-shot mold to prevent the sheet 20 from being displaced, wherein the positioning can be performed by the positioning hole or the positioning needle.
  • the sheet 20 needs to be quickly placed into the first shot mold. For example, the mechanical arm can be taken and placed.
  • the first shot mold is clamped to the high pressure press synthesis type of the sheet material, and the infrared heated sheet material 20 is pressed into a 3D shape (ie, a three-dimensional shape of the product to be produced), and the hard rubber material is injected (ie, a plastic material).
  • the pressure of the high pressure in the step may be in the range of 800 N/cm 2 to 1500 N/cm
  • the hard rubber material may be a glass fiber reinforced composite material such as PC (Polycarbonate: polycarbonate) + 50% GF (glass fiber), PA (Polyamide (nylon): polyamide) + 50% GF, PPS (Poly phenylene sulfide), 50% GF, PBT (Poly butylene terephthalate, polyterephthalic acid) Butadiene ester) + 30% GF.
  • PC Polycarbonate: polycarbonate
  • PA Polyamide (nylon): polyamide
  • PPS Poly phenylene sulfide
  • 50% GF Poly phenylene sulfide
  • PBT Poly butylene terephthalate, polyterephthalic acid
  • Butadiene ester 30% GF.
  • the hard rubber material functions as a structural skeleton after being formed.
  • Injection molding of hard rubber materials can be formed by high-low temperature rapid prototyping (RHCM) molding, which can reduce floating fiber and enhance appearance; of course, it can also adopt Rapid Heat Cycle Molding (RHCM) and micro-foam molding ( Micro cellular Foamine, Mucell) is a combination of composite molding that not only reduces the floating fiber and enhances the appearance, but also reduces warpage.
  • RHCM rapid prototyping
  • RHCM Rapid Heat Cycle Molding
  • Micro-foam molding Micro cellular Foamine, Mucell
  • the sheet 20 after pressing and molding the hard rubber material is rotated into a second shot mold of the two-shot mold to mold the soft rubber material.
  • the soft rubber material functions to cushion shock absorption and waterproof after molding.
  • the soft rubber material is a thermoplastic elastomer, and the hardness is selected according to customer's design requirements, such as TPU (Covestro 9370AU), TPSiv (such as Dow Corning 3340-70A), polyester elastomer TPEE (Dupont Hytrel series TPEE material, DSM Arnitel). Series TPEE material).
  • the first shot mold and the second shot mold of the two-shot mold are provided with a water path (also referred to as a water channel), and steam or cooling water is introduced into the water path to make the first shot mold and the second shot mold
  • a water path also referred to as a water channel
  • steam or cooling water is introduced into the water path to make the first shot mold and the second shot mold
  • the heating and cooling speed is 2°C/s-5°C/s, and the heating and cooling speed is fast, which makes the molding time short and high in efficiency, and can meet the requirements of mass production in the 3C industry.
  • the sheet material 20 is cut to a desired size, such as a length of 350 mm, a width of 255 mm, and a thickness of 1.5 mm.
  • the hole position is processed by milling or punching.
  • the sheet material 20 is placed in the infrared oven 10 for heating, and the temperature is rapidly raised to 200 °C.
  • the bijective mold is heated by steaming, the surface of the bijective mold is heated to 120 ° C - 140 ° C, and the heated sheet 20 is placed in the first shot mold and positioned.
  • the first shot mold is clamped to the high pressure, and the heated sheet 20 is pressed into a 3D shape, and the hard rubber material is injection molded, and the hard rubber material is PC+50% GF.
  • the pressure of the high pressure in the step may be in the range of 800 N/cm to 1500 N/cm.
  • the plate 20 after pressing and molding the hard rubber material is rotated and placed in the second shot mold, and the second shot mold is clamped and injected into the soft rubber material (ie, the second plastic material), such as TPU (Thermoplastic polyurethanes, thermoplastic). Polyurethane elastomer rubber), more specifically 9370 AU of Shore 70A.
  • the soft rubber material ie, the second plastic material
  • TPU Thermoplastic polyurethanes, thermoplastic.
  • Polyurethane elastomer rubber more specifically 9370 AU of Shore 70A.
  • the sheet 20 is cut to a desired size, such as 350 mm in length, 255 mm in width, and 1.0 mm in thickness.
  • the hole position is processed by milling or punching.
  • the sheet material 20 is placed in the infrared oven 10 for heating, and the temperature is rapidly raised to 200 °C.
  • the bijective mold is heated by steaming, the surface of the bijective mold is heated to 120 ° C - 140 ° C, and the heated sheet 20 is placed in the first shot mold and positioned.
  • the first shot mold is clamped to a high pressure, and the heated sheet 20 is pressed into a 3D shape, and the hard rubber material is injection molded, and the hard rubber material is PA+50% GF.
  • the pressure of the high pressure in the step may be in the range of 800 N/cm to 1500 N/cm.
  • the sheet 20 after pressing and molding the hard rubber material is rotated into the second shot mold, and the second shot mold is molded and injection molded with a soft material such as Dupont Hytrel series TPEE material.
  • FIG. 3 shows a schematic diagram of a product of the embodiment.
  • the embodiment further provides a product which is produced after the above-mentioned thermoplastic composite material production method, that is, the product is formed with a hard rubber material structure 21 and a soft rubber material on the pressed plate material 20.
  • the hard rubber material structure 21 functions as a structural skeleton
  • the soft rubber material structure 22 functions as a shock absorbing and waterproofing function, thereby obtaining a product that is strong, thin, and functional.
  • the product may be an electronic and electrical device such as a notebook computer, a tablet computer, a portable telephone, a portable terminal or a camera, or an outer casing of an information device.
  • the manufacturing method of the thermoplastic composite material product of the present embodiment is combined with the insert molding and the bijection method, that is, by heating the thermoplastic composite material sheet by infrared heating, and directly heating into the double shot mold.
  • a shot mold is pressed into a 3D shape and injection molded into a hard rubber material to act as a structural skeleton, and then rotated into a second shot mold of a double shot mold to injection mold soft material to cushion shock absorption and waterproof.
  • the infrared heating rate can reach 5 ° C / s -20 ° C / s, and the heating rate is extremely fast, which can save a lot of Time, and the steam and cooling water heat and cool the two-shot mold.
  • the heating rate and temperature drop rate of the double-shot mold can reach 2°C/s-5°C/s during the molding process, which makes the molding time short and the efficiency high. 3C industry requirements for mass production.
  • the manufacturing method of the thermoplastic composite material provided by the embodiment, combined with the insert molding and the double shot method, can simultaneously obtain a strong, light and functional product, improve the overall yield, and the process is simple; and the infrared heating heating rate can be It reaches 5°C/s-20°C/s, and the heating rate is extremely fast, which can save a lot of time, and the steam and cooling water heat and cool the double-shot mold.
  • the heating rate and cooling speed of the double-shot mold can reach 2 during the molding process. °C / s -5 ° C / s, so that the molding time is short, high efficiency, to meet the requirements of mass production in the 3C industry.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Toxicology (AREA)
  • Oral & Maxillofacial Surgery (AREA)
  • Thermal Sciences (AREA)
  • Electromagnetism (AREA)
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  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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Abstract

一种热塑性复合材料产品的制作方法，包括：对热塑性复合材料板材采用红外加热的方式加热，加热后直接放入双射模具的第一射模具中压合成待制作产品的立体形状，并注塑硬胶材料，旋转进入双射模具的第二射模具中注塑软胶材料，以及第二射模具开模，以取出产品。

Description

热塑性复合材料产品及其制作方法 技术领域
本公开属于复合材料产品的制作领域，例如涉及一种热塑性复合材料产品及其制作方法。
背景技术
随着笔记本电脑、平板电脑、手机、相机、便携式信息终端设备等电子电气设备、信息设备的发展，市场上强烈要求开发出薄型且轻质的产品。轻薄的产品会构成产品的外壳或内部部件薄壁，在产品要求轻薄的同时还要求具有高强度及高刚性。
热塑性复合材料具有质量轻、比强度和比模量高、抗化学腐蚀、耐疲劳、易于整体成型等优点，被广泛应用于制作军工、飞机、风电等产品上。由于热塑性复合材料的优良的力学性能，所以也可以广泛用于笔记本电脑、平板电脑、便携式电话、便携式终端或相机等电子电气设备、信息设备的外壳中，发挥了使外壳薄壁化、减轻设备重量等作用。
目前，电子产品所用复合材料制品，多为先用热压模具压合成所需形状结构，再埋入模具中注塑成型的方法进行加工：
1、对于热固性复合板材，需要将预浸布按要求铺叠后放在热压模具内进行压合固化成所需形状，再放入塑胶模具中注塑成型。然而，该操作方式的缺点为预浸布成型约为30分钟，成型周期长，热压后的板材需要再进行铣切加工，到最终产品的实现需要热压模具压合和塑胶模具注塑成型两个程序，制程较复杂，导致效率低、成本高。
2、对于热塑性复合板材，板材裁切后放在热压模具内压合成所需形状，再放入塑胶模具中注塑成型。该操作方式的缺点是产品实现的整个制程需要热压模具压合和塑胶模具注塑成型两个程序，制程较复杂，导致效率低、成本高，无法满足3C(Computer Communication Consumer Electronic，电脑通讯消费性电子)行业大批量生产的需要。
发明内容
因此，本公开提供一种全新的热塑性复合材料产品的制作方法，该制作方法结合嵌件成型(Insert Molding)与双射方式成型产品，制程简单，效率高，适合大批量生产。
一种热塑性复合材料产品的制作方法，包括：
根据待制作的产品的形状裁切板材，所述板材为热塑性复合材料的板材；
将裁切后的板材进行红外加热；
将红外加热后的板材置入双射模具的第一射模具中进行定位；
所述第一射模具合模进行对定位后的板材进行压合成型，并注塑第一塑胶材料；
压合注塑后的板材旋转置入双射模具的第二射模具中，注塑第二塑胶材料，其中，第二塑胶材料比第一塑胶材料软；以及
第二射模具开模，以取出产品。
可选的，所述板材为含有碳纤维、含有玻璃纤维或同时含有碳纤维以及玻璃纤维的热塑性复合材料板材。
可选的，所述将裁切后的板材进行红外加热，包括采用红外烤箱对裁切后的板材进行红外加热，所述红外烤箱的顶部及底部分别设有温度感应器及依序排列的多个红外线灯管，且红外烤箱中还设有可移动的镂空托盘。
可选的，所述将裁切后的板材进行红外加热，包括：
将裁切后的板材放置到镂空托盘上，镂空托盘滑至红外烤箱中；以及
红外线灯管加热板材，温度感应器检测温度是否达标。
可选的，将裁切后的板材进行红外加热过程中，红外加热的温度在热塑性复合材料板材所使用的树脂的玻璃转化温度与熔融温度之间。
可选的，所述第一塑胶材料为含玻璃纤维增强的复合材料。
可选的，所述注塑第一塑胶材料包括：采用高低温快速成型方式或高低温快速成型与微发泡成型的复合方式将所述第一塑胶材料注塑成型。
可选的，所述第二塑胶材料为热塑性弹性体。
可选的，所述双射模具的第一射模具及第二射模具中设有水路，所述水路中通入蒸汽或冷却水。
一种根据上述任一项所述的热塑性复合材料产品的制作方法制作的产品。
相较于相关技术，本公开的热塑性复合材料产品的制作方法，结合嵌件成 型与双射方式，即通过对热塑性复合材料板材采用红外加热的方式加热，加热后直接放入双射模具的第一射模具中压合成3D形状，并注塑成型硬胶材料，起到结构骨架作用，然后旋转进入双射模具的第二射模具中注塑成型软胶材料，起到缓冲减震、防水作用。由此，可以同时得到强固轻薄兼具功能性的产品，提升了整体良率，且制程简单；另外红外加热升温速度能达到5℃/s-20℃/s，升温速度特别快，能够节约大量时间，且蒸汽和冷却水对双射模具加热及冷却，成型过程中双射模具的升温速度和降温速度均能达到2℃/s-5℃/s，使成型时间短，效率高，能够满足3C行业大批量生产的要求。
附图概述
图1绘示本实施例热塑性复合材料产品的制作方法的步骤流程图。
图2绘示本实施例热塑性复合材料产品的制作方法中红外加热的结构示意图。
图3绘示本实施例的一热塑性复合材料产品的结构示意图。
具体实施方式
在不冲突的情况下，以下实施例和实施例中的特征可以相互组合。请参阅图1至图3所示，其中图1绘示了本实施例热塑性复合材料产品的制作方法的步骤流程图，图2绘示了本实施例热塑性复合材料产品的制作方法中红外加热的结构示意图，图3绘示了本实施例一热塑性复合材料产品的结构示意图。
本实施例的热塑性复合材料产品的制作方法中所述的双射模具，具有第一射模具及第二射模具，第一射模具和第二射模具的公模完全相同，而母模不同。在第一射模具开模后，第一射模具的公模会带动产品旋转到第二射模具处，与第二射模具的母模配合；同时第二射模具的公模会旋转到第一射模具处，与第一射模具的母模配合。
本实施例的热塑性复合材料产品的制作方法，包括：S100-S600。
在S100中，依产品形状裁切板材20，所述板材20可为含碳纤维、玻璃纤维或碳纤维玻璃纤维混合的热塑性复合材料板材20。
在S200中，将裁切后的板材20进行红外加热，即将裁切好的板材20放入红外烤箱10中进行快速加热，红外加热的功率可调，红外烤箱10的顶部及底部分 别设有依序排列的多个红外线灯管11，该红外线灯管11之间的距离可调，其中红外线灯管11使用的红外线波长与热塑性复合材料的波长相同，能够提高加热效率，且红外烤箱10的顶部及底部还分别设有温度感应器12，用以感测温度是否达标。
将裁切后的板材20进行红外加热的具体步骤为：将裁切后的板材20放置到镂空托盘13上，镂空托盘13滑至红外烤箱中；红外线灯管11加热板材20，温度感应器12检测温度是否达标。红外加热的升温速度为5℃/s(摄氏度/秒)-20℃/s，能够使板材10表面的温度快速升温到热塑性复合材料板材10所使用的树脂的玻璃转化温度与熔融温度之间，此时板材20变软，但不会有熔融的液体滴下。
在S300中，将红外加热后的板材20置入双射模具的第一射模具中定位，防止板材20移位，其中可以通过定位孔或定位针进行定位。为了防止红外加热后的板材20热量损失，需快速将板材20置入第一射模具中，例如，可采取机械手臂抓取、置放的方式。
在S400中，第一射模具合模对所述板材进行高压压合成型，将红外加热后的板材20压合成3D形状(即待制作的产品的立体形状)，并注塑硬胶材料(即第一塑胶材料)。其中，该步骤中高压的压力大小可以是处于800牛/平方厘米至1500牛/平方厘米范围内，所述硬胶材料可为玻璃纤维增强的复合材料，如PC(Polycarbonate：聚碳酸酯)+50％GF(玻璃纤维)、PA(Polyamide(nylon)：聚酰胺)+50％GF、PPS(Poly phenylene sulfide，聚苯硫醚)+50％GF、PBT(Poly butylene terephthalate，聚对苯二酸丁二酯)+30％GF。该硬胶材料成型后起到结构骨架作用。
注塑硬胶材料时可以采用高低温快速成型方式(RHCM)成型，可以降低浮纤和提升外观；当然，还可以采用高低温快速成型方式(Rapid Heat Cycle Molding，RHCM)与微发泡成型方式(Micro cellular Foamine，Mucell)相结合的复合方式成型，不仅可以降低浮纤和提升外观，还可以降低翘曲变形。
在S500中，压合及注塑硬胶材料后的板材20旋转置入双射模具的第二射模具中，注塑软胶材料。所述软胶材料成型后起到缓冲减震、防水等作用。
所述软胶材料为热塑性弹性体，硬度依据客户设计需求选择，如可为TPU(Covestro 9370AU)、TPSiv(如Dow Corning 3340-70A)、聚酯弹性体TPEE(Dupont Hytrel系列TPEE材质、DSM Arnitel系列TPEE材质)。
在S600中，第二射模具开模，取出产品，一个循环结束。
其中，所述双射模具的第一射模具及第二射模具中设有水路(又可以称为水道)，所述水路中通入蒸汽或冷却水，使第一射模具和第二射模具升温及降温的速度为2℃/s-5℃/s，升温及降温速度快，使成型时间短，效率高，能够满足3C行业大批量生产的要求。
具体实施例如下。
实施例1
以PC树脂热塑性碳纤板成型笔记本电脑A件产品为例。
在S101中，将板材20裁剪成所需尺寸，如长350mm，宽255mm，厚1.5mm。其中，孔位通过铣切或冲裁加工。
在S201中，将板材20放入红外烤箱10中进行加热，快速升温到200℃。
在S301中，通入蒸汽对双射模具进行加热，将双射模具的表面加热到120℃-140℃，将加热后的板材20放入第一射模具中并定位。
在S401中，第一射模具合模锁高压，将加热后的板材20压合成3D形状，并注塑硬胶材料，硬胶材料如为PC+50％GF。其中，该步骤中高压的压力大小可以是处于800牛/平方厘米至1500牛/平方厘米范围内。
在S501中，压合及注塑硬胶材料后的板材20旋转置于第二射模具中，第二射模具合模并注塑软胶材料(即第二塑胶材料)，如TPU(Thermoplastic polyurethanes，热塑性聚氯酯弹性体橡胶)，更具体地可为Shore 70A的9370AU。
在S601中，第二射模具开模，取出产品，一个循环结束。
实施例2
以PA树脂热塑性碳纤板成型笔记本电脑D件产品为例。
在S102中，将板材20裁剪成所需尺寸，如长350mm，宽255mm，厚1.0mm。其中，孔位通过铣切或冲裁加工。
在S202中，将板材20放入红外烤箱10中进行加热，快速升温到200℃。
在S302中，通入蒸汽对双射模具进行加热，将双射模具的表面加热到120℃-140℃，将加热后的板材20放入第一射模具中并定位。
在S402中，第一射模具合模锁高压，将加热后的板材20压合成3D形状，并注塑硬胶材料，硬胶材料如为PA+50％GF。其中，该步骤中高压的压力大小可以是处于800牛/平方厘米至1500牛/平方厘米范围内。
在S502中，压合及注塑硬胶材料后的板材20旋转置于第二射模具中，第二射模具合模并注塑软胶材料，如Dupont Hytrel系列TPEE材质。
在S602中，第二射模具开模，取出产品，一个循环结束。
另外，请参阅图3所示，其绘示了本实施例的一种产品的示意图。本实施例还提供一种产品，该产品为经上述热塑性复合材料产品的制作方法制作后产生的产品，即所述产品在压合后的板材20上成型有硬胶材料结构21及软胶材料结构22，所述硬胶材料结构21起到结构骨架作用，所述软胶材料结构22起到缓冲减震、防水作用等，由此可以得到强固轻薄兼具功能性的产品。
所述产品可为笔记本电脑、平板电脑、便携式电话、便携式终端或相机等电子电气设备、信息设备的外壳。
综上所述，本实施例的热塑性复合材料产品的制作方法，结合嵌件成型与双射方式，即通过对热塑性复合材料板材采用红外加热的方式加热，加热后直接放入双射模具的第一射模具中压合成3D形状，并注塑成型硬胶材料，起到结构骨架作用，然后旋转进入双射模具的第二射模具中注塑成型软胶材料，起到缓冲减震、防水作用。由此，可以同时得到强固轻薄兼具功能性的产品，提升了整体良率，且制程简单；另外红外加热升温速度能达到5℃/s-20℃/s，升温速度特别快，能够节约大量时间，且蒸汽和冷却水对双射模具加热及冷却，成型过程中双射模具的升温速度和降温速度均能达到2℃/s-5℃/s，使成型时间短，效率高，能够满足3C行业大批量生产的要求。
工业实用性
本实施例提供的热塑性复合材料产品的制作方法，结合嵌件成型与双射方式，可以同时得到强固轻薄兼具功能性的产品，提升了整体良率，且制程简单；另外红外加热升温速度能达到5℃/s-20℃/s，升温速度特别快，能够节约大量时间，且蒸汽和冷却水对双射模具加热及冷却，成型过程中双射模具的升温速度和降温速度均能达到2℃/s-5℃/s，使成型时间短，效率高，能够满足3C行业大批量生产的要求。

Claims (10)

  1. 一种热塑性复合材料产品的制作方法，包括：
    根据待制作的产品的形状裁切板材，所述板材为热塑性复合材料的板材；
    将裁切后的板材进行红外加热；
    将红外加热后的板材置入双射模具的第一射模具中进行定位；
    所述第一射模具合模进行对定位后的板材进行压合成型，并注塑第一塑胶材料；
    压合注塑后的板材旋转置入双射模具的第二射模具中，注塑第二塑胶材料，其中，第二塑胶材料比第一塑胶材料软；以及
    第二射模具开模，以取出产品。
  2. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述板材为含有碳纤维、含有玻璃纤维或同时含有碳纤维以及玻璃纤维的热塑性复合材料板材。
  3. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述将裁切后的板材进行红外加热，包括采用红外烤箱对裁切后的板材进行红外加热，所述红外烤箱的顶部及底部分别设有温度感应器及依序排列的多个红外线灯管，且红外烤箱中还设有可移动的镂空托盘。
  4. 根据权利要求3所述的热塑性复合材料产品的制作方法，其中，所述将裁切后的板材进行红外加热，包括：
    将裁切后的板材放置到镂空托盘上，镂空托盘滑至红外烤箱中；以及
    红外线灯管加热板材，温度感应器检测温度是否达标。
  5. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，将裁切后的板材进行红外加热过程中，红外加热的温度在热塑性复合材料板材所使用的树脂的玻璃转化温度与熔融温度之间。
  6. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述第一塑胶材料为含玻璃纤维增强的复合材料。
  7. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述注塑第一塑胶材料包括：采用高低温快速成型方式或高低温快速成型与微发泡成型的复合方式将所述第一塑胶材料注塑成型。
  8. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述第二塑胶材料为热塑性弹性体。
  9. 根据权利要求1所述的热塑性复合材料产品的制作方法，其中，所述双射模具的第一射模具及第二射模具中设有水路，所述水路中通入蒸汽或冷却水。
  10. 一种根据权利要求1至9中任一项所述的热塑性复合材料产品的制作方法制作的产品。
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