WO2018036271A1 - 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
WO2018036271A1
WO2018036271A1 PCT/CN2017/090866 CN2017090866W WO2018036271A1 WO 2018036271 A1 WO2018036271 A1 WO 2018036271A1 CN 2017090866 W CN2017090866 W CN 2017090866W WO 2018036271 A1 WO2018036271 A1 WO 2018036271A1
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Prior art keywords
thermoplastic composite
sheet
shot mold
infrared
mold
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PCT/CN2017/090866
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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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Publication of WO2018036271A1 publication Critical patent/WO2018036271A1/zh

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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

  • thermoplastic 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 sheet there is also a process of press-molding and mixing, once the sheet is cut, placed in an infrared heating device for infrared heating, and then placed in an injection mold to position and compress the desired shape. And injection molding.
  • the process is relatively simple, but the corresponding mold area at the hole and the hole position is required on the board. Avoiding the air, so the plate needs to be molded at the plastic structure and the hole position will be deformed when pressing, resulting in uneven plate density, uneven appearance, and the problem of overflowing during injection molding.
  • the present disclosure provides a method of making a thermoplastic composite product that results in a product that is uniformly compressed, has a flat appearance, and is free of spills.
  • thermoplastic composite product comprising:
  • the sheet being a sheet of thermoplastic composite material
  • the cut sheet is subjected to infrared heating
  • the first shot mold is clamped and pressed, and the infrared heated sheet is pressed into the three-dimensional shape of the product to be produced;
  • the pressed plate is rotated into a second shot mold of the double shot mold to mold the plastic material
  • the second shot mold is opened to take out the product.
  • thermoplastic composite sheet material is a carbon composite fiber, a glass fiber fiber or a thermoplastic composite material sheet containing both carbon fiber and glass fiber.
  • the cut plate is subjected to infrared heating, comprising infrared heating the cut plate by using an infrared oven; the top and bottom of the infrared oven are respectively provided with a temperature sensor and sequentially arranged.
  • Infrared tubes and a removable hollow tray in the infrared oven are respectively provided with a temperature sensor and sequentially arranged.
  • infrared heating of the cut sheet comprises:
  • the infrared lamp heats the plate, and the temperature sensor detects whether the temperature in the infrared oven is up to standard.
  • no space is disposed between the first shot mold and the sheet.
  • the area between the second shot mold and the sheet material to be injection molded plastic structure and the corresponding position at the hole position is arranged to avoid the space.
  • the plastic material is a thermoplastic elastomer.
  • the plastic material selects a material having a hardness of Shore D.
  • a water path is disposed in the first shot mold and the second shot mold of the double shot mold.
  • thermoplastic composite material A product produced by the method for producing a thermoplastic composite material according to any of the above.
  • thermoplastic composite material of the present disclosure not only makes the plate density uniform, the appearance is flat, and has no overflow rubber, improves the overall yield, is suitable for mass production, and the injection soft rubber material acts as a cushioning shock absorber and waterproof. Even at the same time to achieve structural and protective effects; in addition, the infrared heating rate can reach 5 ° C / s -20 ° C / s, the heating rate is particularly fast, can save a lot of time, and steam and cooling water heating and cooling the two-shot mold, forming In the process, the heating rate and the cooling rate of the two-shot mold can reach 2 ° C / s - 5 ° C / s, resulting in short molding time and high efficiency, which can meet the requirements of mass production in the 3C industry.
  • thermoplastic composite product of the present embodiment is a flow chart showing a method of 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.
  • FIG. 3 is a schematic illustration of the thermoplastic composite product of the present embodiment.
  • FIG. 1 is a flow chart showing a manufacturing method of the thermoplastic composite material product of the embodiment
  • FIG. 2 is a diagram showing the structure of the infrared heating structure in the manufacturing method of the thermoplastic composite material product of the embodiment
  • FIG. 3 is a schematic view of the 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.
  • thermoplastic composite sheet 20 is cut according to the shape of the product, and the thermoplastic composite sheet is a thermoplastic composite sheet containing pure 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 of the infrared oven 10 are respectively arranged in sequence.
  • the infrared lamp 11 uses the same infrared wavelength as the thermoplastic composite material to increase the heating efficiency, and the temperature sensor 12 is also provided at the top and bottom of the infrared oven 10 to sense 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 to the infrared oven 10; the infrared tube 11 heating the sheet 20, the temperature sensor 12 Check if the temperature is up to standard.
  • the heating rate of the infrared heating is 5 ° C / s -20 ° C / s, which can rapidly increase the temperature of the surface of the sheet 20 to the glass transition temperature and the melting temperature of the resin used in the thermoplastic composite sheet 20, at which time the sheet 20 becomes Soft, but there will be no molten liquid dripping.
  • 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 and subjected to high pressure pressing, and the infrared heated sheet 20 is pressed into a 3D shape (that is, a three-dimensional shape of the product to be produced).
  • the first shot mold and the sheet material 20 are not provided with air escaping, so that the sheet material 20 is uniformly and pressure-formed, and the density of the sheet material 20 is prevented from being uneven, which provides convenience for the next step.
  • the pressure of the high pressure in the step may be in the range of 800 N/cm to 1500 N/cm.
  • the pressed plate 20 is rotated into the second shot mold of the double shot mold, and the soft rubber material is injected, and the soft rubber material is used to cushion shock absorption and waterproof.
  • the area between the second shot mold and the sheet 20 that needs to be injection molded plastic structure and the corresponding position at the hole position is arranged to avoid the space, which is convenient for injection molding, and since the sheet material 20 has been uniformly pressurized, there is no problem of overflowing during injection molding.
  • injection molding soft material is formed by a combination of Rapid Heat Cycle Molding (RHCM) and Microcellular Foamine (Mucell), it can improve the shockproof effect and dimensional stability.
  • the soft rubber material is a thermoplastic elastomer, and the hardness is selected according to customer design requirements, such as polyester elastomer TPEE (Dupont Hytrel_6356, Hytrel_4056, DSM Arnitel series TPEE material, etc.); the soft rubber material can also be selected to have a hardness of Shore (Shao The soft rubber material of D) not only achieves shock absorption and water repellency, but also has a high hardness and can also shape the formed structure, such as the material of Shore D60.
  • a water path is provided in the first shot mold and the second shot mold of the two-shot mold, wherein the water path is Steam or cooling water is introduced to increase the temperature of the first and second shot molds by 2 ° C / s - 5 ° C / s, and the temperature rise and temperature drop are fast, so that the molding time is short, the efficiency is high, and the 3C can be satisfied. Industry requirements for mass production.
  • 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 a high pressure, and the heated sheet material 20 is pressed into a 3D shape.
  • the pressure of the high pressure in the step may be in the range of 800 N/cm to 1500 N/cm.
  • the pressed plate 20 is rotated into the second shot mold, the second shot mold is clamped and the soft material is injected, and the soft rubber material used for the injection molding is Dupont Hytrel_6356.
  • the sheet material 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.
  • the pressure of the high pressure in the step may be in the range of 800 N/cm to 1500 N/cm.
  • the pressed plate 20 is rotated in the second shot mold, the second shot mold is clamped and the soft rubber material is injected, and the soft rubber material used for the injection molding is made of DSM Arnitel series TPEE material.
  • the present 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 soft rubber material structure 21 on the pressed plate material 20,
  • the soft material structure 21 serves as a structure for shaping and protection, thereby obtaining a strong and thin Functional product.
  • 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 method for manufacturing the thermoplastic composite material of the present embodiment is heated by infrared heating on the thermoplastic composite material sheet 20, and is directly pressed into the first shot mold of the double shot mold to be pressed. 20 Fully balanced and pressure-molded, and then rotated into the second shot mold of the two-shot mold to mold the soft rubber material. Therefore, the press-bonding and the injection molding are carried out separately, so that the plate 20 has a uniform density, a flat appearance, and no overflow rubber, thereby improving the overall yield, and is suitable for mass production, and the injection molding soft material is used for cushioning shock absorption and waterproofing.
  • the infrared heating rate can reach 5 ° C / s -20 ° C / s, the heating rate is particularly fast, can save a lot of time, and steam and cooling water heating and cooling the two-shot mold
  • the heating rate and the cooling rate of the double-shot mold can reach 2°C/s-5°C/s, which is short in molding time and high in efficiency, and can meet the requirements of mass production in the 3C industry.
  • the manufacturing method of the thermoplastic composite material separates the pressing and the injection molding, not only makes the plate density uniform, the appearance is flat, and there is no overflow rubber, thereby improving the overall yield, suitable for mass production, and injection molding soft rubber.
  • the material plays the role of buffering shock absorption and waterproofing, and even achieves the structure and protection at the same time; in addition, the infrared heating heating rate can reach 5 ° C / s -20 ° C / s, the heating rate is extremely fast, can save a lot of time, and steam and cooling Water heating and cooling the two-shot mold, the heating rate and cooling speed of the two-shot mold can reach 2 °C / s -5 ° C / s during the molding process, resulting in short molding time and high efficiency, which can meet the mass production of 3C industry. Requirements.

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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，旋转进入双射模具的第二射模具中注塑塑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
本公开属于热塑性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。
3、对于热塑性复合板材，还有一种制程即为压合注塑混合一次制程，具体为将板材裁切后放入红外加热装置中进行红外加热，然后再放入注塑模具中定位压合成所需形状，并注塑成型。
然而，对于压合注塑混合一次制程，虽然不需要经过热压模具压合和塑胶模具注塑成型两个程序，制程较简单，但由于板材上需要注塑塑胶结构处及孔位处对应的模具区域是避空的，因此压合时板材需要注塑塑胶结构处及孔位处会变形，导致板材密度不均，外观不平整，在注塑时且有溢胶的问题。
综上所述，上述压合注塑混合一次制程中存在板材密度不均、外观不平整及溢胶的问题。
发明内容
因此，本公开提供一种热塑性复合材料产品的制作方法，该制作方法可以得到板材均匀受压、外观平整且无溢胶的产品。
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定位；
所述第一射模具合模进行压合，将红外加热后的板材压合成所述待制作的产品的立体形状；
压合后的板材旋转置入双射模具的第二射模具中，注塑塑胶材料；以及
第二射模具开模，以取出产品。
可选的，所述热塑性复合材料板材为含碳纤维、含玻璃纤维或同时含碳纤维和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，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，温度感应器检测所述红外烤箱内的温度是否达标。
可选的，所述第一射模具与板材间未设置避空。
可选的，所述第二射模具与板材间需要注塑塑胶结构处及孔位处对应的区域设置避空。
可选的，所述塑胶材料为热塑性弹性体。
可选的，所述塑胶材料选择硬度为Shore D的材料。
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。
一种利用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。
本公开的热塑性复合材料产品的制作方法，不仅使板材密度均匀、外观平整，且无溢胶，提升了整体良率，适合大批量生产，而且注塑软胶材料起到缓冲减震、防水的作用，甚至同时达到结构与保护作用；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，由此成型时间短，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绘示本实施例热塑性复合材料产品的示意图。
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及图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绘示了本实施例热塑性复合材料产品的示意图。
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。
S100中，依产品形状裁切热塑性复合材料板材20，所述热塑性复合材料板材为含纯碳纤维、玻璃纤维或碳纤维玻璃纤维混合的热塑性复合材料板材。
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10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-20℃/s，能够使板材20表面的温度快速升温到热塑性复合材料板材20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。
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。
S400中，第一射模具合模进行高压压合，将红外加热后的板材20压合成3D形状(即待制作产品的立体形状)。其中，第一射模具与板材20间未设置避空，以使板材20全面均衡受压成型，防止板材20密度不均，为下一步骤提供方便。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/平方厘米的范围内。
S500中，压合后的板材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。其中，第二射模具与板材20间需要注塑塑胶结构处及孔位处对应的区域设置避空，方便注塑，且由于板材20已均衡受压，注塑时不会出现溢胶的问题。注塑软胶材料时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，能够提升防震效果和尺寸稳定性。
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，如聚酯弹性体TPEE(Dupont Hytrel_6356、Hytrel_4056、DSM Arnitel系列TPEE材质等)；所述软胶材料还可选择硬度为Shore(邵氏)D的软胶材料，不仅能达到缓冲减震、防水作用，且由于硬度比较高同时还可对形成的结构起到定型作用，如Shore D60的材料。
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，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。
现结合具体实施例详细说明如下。
实施例1
以PA树脂热塑性碳纤板成型笔记本电脑A件产品为例。
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。
S201中，将板材20放入红外烤箱10中进行加热，快速升温到200℃。
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。
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。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。
S501中，压合后的板材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，注塑所用软胶材料如Dupont Hytrel_6356。
S601中，第二射模具开模，取出产品，一个循环结束。
实施例2
以PBT树脂热塑性玻纤板成型笔记本电脑D件产品为例。
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。
S202中，将板材20放入红外烤箱10中进行加热，快速升温到200℃。
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。
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。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。
S502中，压合后的板材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，注塑所用软胶材料如DSM Arnitel系列TPEE材质。
S602中，第二射模具开模，取出产品，一个循环结束。
另外，本实施例还提供一种产品，其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上成型有软胶材料结构21，所述软胶材料结构21起到结构定型与保护作用，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，通过对热塑性复合材料板材20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，使板材20全面均衡受压成型，然后旋转进入双射模具的第二射模具中注塑软胶材料。由此，将压合与注塑成型分开进行，不仅使板材20密度均匀、外观平整，且无溢胶，提升了整体良率，适合大批量生产，而且注塑软胶材料起到缓冲减震、防水的作用，甚至同时达到结构与保护作用；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，由此成型时间短，效率高，能够满足3C行业大批量生产的要求。
工业实用性
本公开提供的热塑性复合材料产品的制作方法，将压合与注塑成型分开进行，不仅使板材密度均匀、外观平整，且无溢胶，提升了整体良率，适合大批量生产，而且注塑软胶材料起到缓冲减震、防水的作用，甚至同时达到结构与保护作用；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，由此成型时间短，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定位；
    所述第一射模具合模进行压合，将红外加热后的板材压合成所述待制作的产品的立体形状；
    压合后的板材旋转置入双射模具的第二射模具中，注塑塑胶材料；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，所述热塑性复合材料板材为含碳纤维、含玻璃纤维或同时含碳纤维和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，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，温度感应器检测所述红外烤箱内的温度是否达标。
  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，所述第一射模具与板材间未设置避空。
  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，所述第二射模具与板材间需要注塑塑胶结构处及孔位处对应的区域设置避空。
  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，所述塑胶材料为热塑性弹性体。
  8. 根据权利要求1或7所述的热塑性复合材料产品的制作方法，其中，所述塑胶材料选择硬度为Shore D的材料。
  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。
  10. 一种利用权利要求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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