WO2021128191A1

WO2021128191A1 - Carbon fiber dome manufacturing method

Info

Publication number: WO2021128191A1
Application number: PCT/CN2019/128812
Authority: WO
Inventors: 狄勋; 陈敏敏; 赵彬
Original assignee: 瑞声声学科技(深圳)有限公司; 瑞声科技(新加坡)有限公司
Priority date: 2019-12-26
Filing date: 2019-12-26
Publication date: 2021-07-01

Abstract

The present application relates to the field of electroacoustic devices, and particularly relates to a carbon fiber dome manufacturing method. The manufacturing method comprises: when cutting a carbon fiber dome into a predetermined shape, performing cutting in a cutting direction having an included angle with respect to the direction of extension of carbon fibers. In the manufacturing method of the present application, no given edge of the cut dome is parallel to the direction of extension of the carbon fibers, thereby avoiding the occurrence of cracking on the edges of the cut dome and preventing a crack from exposing the carbon fibers, and accordingly improving the pure-tone effects and reliability of loudspeaker products using the carbon fiber dome.

Description

Method for manufacturing carbon fiber dome

【Technical Field】

This application relates to the field of electroacoustic devices, and in particular to a method for manufacturing a carbon fiber dome.

【Background technique】

When cutting the carbon fiber dome of the prior art, the cutting method shown in FIG. 1 is adopted, that is, the dome 100 is a racetrack shape, the long axis direction is perpendicular to the extending direction of the carbon fiber, and the short axis direction is parallel to the extending direction of the carbon fiber. The short edge of the dome 100 formed by cutting is easy to crack, which easily causes the carbon fiber yarn to be exposed, which in turn causes the pure sound and reliability of the speaker product to be affected.

Therefore, it is necessary to provide a new technical solution to solve the above technical problems.

[Summary of the invention]

The present application provides a method for manufacturing a carbon fiber dome, which can solve the technical problem that the edge of the carbon fiber dome is prone to cracking in the prior art.

The technical solution of the present application is as follows: a method for manufacturing a carbon fiber dome is provided. In the process of cutting the carbon fiber dome into a predetermined shape, the carbon fiber dome is cut along a cutting direction at an angle with the extending direction of the carbon fiber. Carbon fiber dome for cutting.

Preferably, the angle between the cutting direction and the extending direction of the carbon fiber is 5° to 85°.

Preferably, the cutting is laser cutting, trimming die punching, or die cutting machine die cutting.

Preferably, the manufacturing method further includes:

The carbon fiber unidirectional tape is pre-impregnated with prepreg resin to obtain the prepreg carbon fiber unidirectional tape;

One layer of the pre-impregnated carbon fiber unidirectional tape is cured, or at least two layers of the pre-impregnated carbon fiber unidirectional tape are bonded to each other and then cured to obtain a carbon fiber dome. The angle between the fiber directions of the two layers of the carbon fiber unidirectional belt is 0°-90°.

Preferably, the number of layers of the carbon fiber unidirectional tape prepreg in the carbon fiber dome is 1-20 layers.

Preferably, the manufacturing method further includes:

One or more layers of the pre-impregnated carbon fiber unidirectional tape are pasted on the upper surface and/or lower surface of the foamed material layer and then cured to obtain a carbon fiber dome, wherein the two adjacent layers of carbon fiber The fiber direction included angle of the unidirectional belt is 0°～90°.

Preferably, the manufacturing method includes:

The carbon fiber dome is cut along a first cutting direction to form the first long side and the second long side of the carbon fiber dome, wherein the first cutting direction is the same as each layer of carbon fiber unidirectional tape prepreg The extending directions of the medium carbon fibers are all at an angle;

The carbon fiber dome is cut along a second cutting direction to form a first short side and a second short side of the carbon fiber dome, wherein the second cutting direction is perpendicular to the first cutting direction, so The second cutting direction and the extending direction of the carbon fibers in each layer of the carbon fiber unidirectional tape prepreg are at an angle.

Preferably, the thickness of the carbon fiber unidirectional tape prepreg is 5 μm-100 μm;

And/or, the mass fraction of the prepreg resin in the carbon fiber unidirectional tape prepreg is 10% to 55%;

And/or, the prepreg resin includes epoxy resin, polyetheretherketone, polyimide, polyphenylene sulfide, polyparaphenylene benzodioxazole and polyparaphenylene terephthalamide. One or more

And/or, the tensile modulus of the carbon fiber material in the carbon fiber unidirectional belt is greater than 200 Gpa;

And/or, the thickness of the carbon fiber dome is 20 μm to 2000 μm.

Preferably, the foamed material layer includes one or more of polyethylene terephthalate, polymethacrylimide, polyimide, polypropylene, and polyphenylene sulfide.

Preferably, the thickness of the carbon fiber dome is 80 μm to 200 μm.

The beneficial effect of the present application is that when the manufacturing method of the present application cuts the carbon fiber dome into a preset shape, the cutting direction and the extending direction of the carbon fiber are at an angle, and the edges of the cut dome are not extended by the carbon fiber. The directions are parallel to prevent the edge of the dome formed by cutting from cracking and causing the carbon fiber to be exposed, thereby improving the pure sound effect and reliability of the speaker product using the carbon fiber dome.

【Explanation of the drawings】

Fig. 1 is a schematic diagram of cutting a carbon fiber dome in the prior art;

2 is a schematic diagram of cutting in a method for manufacturing a carbon fiber dome provided by an embodiment of the application;

FIG. 3 is another schematic diagram of cutting in the manufacturing method of the carbon fiber dome provided by the embodiment of the application; FIG.

4 is a flowchart of a method for manufacturing a carbon fiber dome provided in Embodiment 1 of the application;

5 is a flowchart of a method for manufacturing a carbon fiber dome provided in Embodiment 2 of the application;

FIG. 6 is a flowchart of a method for manufacturing a carbon fiber dome provided in Embodiment 3 of the application.

【Detailed ways】

The following will clearly and completely describe the technical solutions in the embodiments of the present application in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in this application, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of this application.

The terms "first", "second", and "third" in this application are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, the features defined with “first”, “second”, and “third” may explicitly or implicitly include at least one of the features. In the description of this application, "a plurality of" means at least two, such as two, three, etc., unless otherwise specifically defined. All directional indicators (such as up, down, left, right, front, back...) in the embodiments of this application are only used to explain the relative positional relationship between the components in a specific posture (as shown in the drawings) , Movement status, etc., if the specific posture changes, the directional indication will also change accordingly. In addition, the terms "including" and "having" and any variations of them are intended to cover non-exclusive inclusions.

The reference to "embodiments" herein means that a specific feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various places in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment mutually exclusive with other embodiments. Those skilled in the art clearly and implicitly understand that the embodiments described herein can be combined with other embodiments.

The embodiment of the application provides a method for manufacturing a carbon fiber dome. In the process of cutting the carbon fiber dome into a preset shape, the carbon fiber dome is cut along a cutting direction that is the same as the carbon fiber in the carbon fiber dome. The extending direction is an angle.

Wherein, the carbon fiber dome to be cut includes one or more layers of carbon fiber prepreg, and the included angle is preferably 5° to 85°.

Among them, the above-mentioned cutting method may be laser cutting, edge trimming die cutting or die cutting machine die cutting.

In an alternative embodiment, please refer to FIG. 2. The carbon fiber prepreg may be a carbon fiber unidirectional tape prepreg 201, and the extending direction S0 of the carbon fiber is shown in FIG. 2 as the vertical direction. When the dome containing the carbon fiber unidirectional tape prepreg 201 is rectangularly cut, it needs to be cut in two directions. Among them, the first cutting direction S1 is the long axis direction of the rectangle, and the second cutting direction S2 is the short rectangle. Axis direction, in order to avoid edge cracking of the dome 200 after cutting, neither the long axis direction nor the short axis direction of the rectangle can be the extending direction S0 of the carbon fibers in the carbon fiber unidirectional tape prepreg 201, therefore, the first cutting direction S1 It forms a first angle with the extending direction S0 of the carbon fiber, and the second cutting direction S2 forms a second angle with the extending direction S0 of the carbon fiber. The first and second included angles are respectively greater than 0° and less than 90°, and further Ground, the first included angle and the second included angle are preferably greater than or equal to 5° and less than or equal to 85°, respectively. In this embodiment, the number of layers of the carbon fiber unidirectional tape prepreg in the carbon fiber dome can be 1-20 layers.

In another alternative embodiment, please refer to FIG. 3, the carbon fiber prepreg may be a carbon fiber bidirectional tape prepreg 301, and the extending direction S01 of the carbon fiber is shown in FIG. 3 as the vertical direction. The extension direction S02 of the other carbon fiber. When the dome containing the carbon fiber bidirectional tape prepreg 301 is rectangularly cut, it needs to be cut in two directions. The third cutting direction S3 is the long axis direction of the rectangle. The four cutting direction S4 is the short axis direction of the rectangle. In order to avoid edge chipping of the dome 300 after cutting, neither the long axis direction nor the short axis direction of the rectangle can be the extending direction S01 and the carbon fiber in the carbon fiber bidirectional tape prepreg 301. The extension direction S02 of the other carbon fiber, therefore, the third cutting direction S3 and the extension direction S01 of the carbon fiber form a third angle, and the extension direction S02 of the carbon fiber forms a fourth angle, and the fourth cutting direction S4 is relative to the extension direction S01 of the carbon fiber. The fifth included angle, the sixth included angle with the extending direction S02 of the carbon fiber, the third included angle, the fourth included angle, the fifth included angle, and the sixth included angle are respectively greater than 0° and less than 90°, and further , The third, fourth, fifth, and sixth included angles are respectively greater than or equal to 5° and less than or equal to 85°.

In other optional embodiments, the carbon fiber prepreg may also be a carbon fiber three-way tape prepreg, which includes the extension directions of three carbon fibers, and the cutting direction needs to be at an angle with the extension directions of the three carbon fibers. All included angles are greater than or equal to 5° and less than or equal to 85°.

In other optional embodiments, the carbon fiber dome to be cut may be formed by laminating at least two layers of carbon fiber prepreg, each layer of carbon fiber prepreg includes at least one carbon fiber extension direction, and the cutting direction needs to be consistent with each layer of carbon fiber prepreg. The extending directions of the carbon fibers of the dipping material are at an angle, and all the angles are greater than or equal to 5° and less than or equal to 85°.

In other optional embodiments, the carbon fiber dome to be cut may also include a substrate layer or an intermediate layer composited with carbon fiber prepreg, the substrate layer or intermediate layer has an upper surface and a lower surface that are arranged oppositely, The upper surface and/or the lower surface are provided with one or more layers of carbon fiber prepreg.

In this embodiment, the thickness of the carbon fiber dome obtained in this embodiment is 20 μm to 2000 μm, preferably 80 μm to 200 μm. The thickness of each layer of the carbon fiber prepreg is 5 μm-100 μm.

Example 1

Please refer to FIG. 2 and FIG. 4, the present application provides a method for manufacturing a carbon fiber dome, which includes the following steps:

In S101, the carbon fiber unidirectional tape is pre-impregnated with a prepreg resin to obtain a prepreg carbon fiber unidirectional tape.

S102, curing the prepreg carbon fiber unidirectional tape to form a carbon fiber dome.

S103, cutting the carbon fiber dome along a first cutting direction to form a first long side and a second long side of the carbon fiber dome.

Wherein, the first cutting direction forms an angle with the extending direction of the carbon fibers in the carbon fiber unidirectional tape prepreg.

S104, cutting the carbon fiber dome along a second cutting direction to form a first short side and a second short side of the carbon fiber dome.

Wherein, the second cutting direction is perpendicular to the first cutting direction, and the second cutting direction forms an angle with the extending direction of the carbon fibers in each layer of carbon fiber unidirectional tape prepreg.

In step S102, the pre-impregnated carbon fiber unidirectional tape is subjected to a hot-press curing treatment to form a carbon fiber unidirectional tape prepreg. In this embodiment, the carbon fiber dome includes a single-layer carbon fiber unidirectional tape prepreg. Specifically, the thickness of the cured carbon fiber unidirectional tape prepreg is 20 μm-100 μm; the mass fraction of the prepreg resin in the cured carbon fiber unidirectional tape prepreg is 10% to 55%.

In step S103 and step S104, the carbon fiber dome is rectangularly cut as shown in FIG. 2.

In this embodiment, the prepreg resin may include epoxy resin, polyether ether ketone (PEEK), polyimide (PI), polyphenylene sulfide (PPS), polyparaphenylene benzodioxazole ( PBO), one or more of poly-p-phenylene terephthalamide (aramid 1414). The tensile modulus of the carbon fiber material in the carbon fiber unidirectional tape prepreg is greater than 200Gpa. The carbon fiber material in the carbon fiber unidirectional tape prepreg can be Toray's T series T300 or above, M series all, and the same strength level For other series and materials from other suppliers, it should be noted that Toray’s T series and M series are carbon fiber models of Toray Corporation in Japan, and those skilled in the art can easily obtain these two series of materials.

Example 2

Please refer to FIG. 5, this application provides a method for manufacturing a carbon fiber dome, which includes the following steps:

In S201, the carbon fiber unidirectional tape is pre-impregnated with a prepreg resin to obtain a prepreg carbon fiber unidirectional tape.

In S202, the two pre-impregnated carbon fiber unidirectional tapes are bonded to each other and then cured to form a carbon fiber dome.

S203: Cut the carbon fiber dome along the first cutting direction to form the first long side and the second long side of the carbon fiber dome.

Wherein, the first cutting direction and the extending direction of the carbon fibers in the two layers of carbon fiber unidirectional tape prepregs both form an angle.

S204, cutting the carbon fiber dome in a second cutting direction to form a first short side and a second short side of the carbon fiber dome.

Wherein, the second cutting direction is perpendicular to the first cutting direction, and the second cutting direction forms an angle with the extending direction of the carbon fibers in the two layers of carbon fiber unidirectional tape prepreg.

The difference between this embodiment and embodiment 1 is that in step S202, the carbon fiber dome obtained after curing contains two layers of carbon fiber prepregs. The extension directions of the carbon fibers in the two layers of carbon fiber prepregs are different. The angle between the fibers is 0°～90°. In this embodiment, the thickness of the cured carbon fiber unidirectional tape prepreg is 10 μm-100 μm; the mass fraction of the prepreg resin in the cured carbon fiber unidirectional tape prepreg is 10% to 55%. The resin content within this range can make the carbon fiber in the carbon fiber unidirectional belt prepreg more compact, so that it has a higher flexural modulus after hot pressing. For other parts that are the same as in Example 1, please refer to the above for details.

Example 3

Please refer to FIG. 6, the present application provides a method for manufacturing a carbon fiber dome, which includes the following steps:

In S301, the carbon fiber unidirectional tape is pre-impregnated with a prepreg resin to obtain a prepreg carbon fiber unidirectional tape.

S302: Paste one or more layers of the pre-impregnated carbon fiber unidirectional tape on the upper surface and/or lower surface of the foamed material layer and then perform curing treatment to obtain a carbon fiber dome.

Wherein, the angle between the fiber directions of the two adjacent layers of carbon fiber unidirectional belts is 0°-90°.

S303: Determine the first cutting direction and the second cutting direction according to the extending directions of the carbon fibers of the carbon fiber prepregs of each layer of the carbon fiber dome.

Wherein, the first cutting direction and the carbon fiber extension direction in each layer of carbon fiber unidirectional tape prepreg are at an angle; the second cutting direction is perpendicular to the first cutting direction, and the second cutting direction is perpendicular to the carbon fiber unidirectional tape prepreg. The extending direction of the carbon fiber in the belt prepreg is at an angle.

S304, cutting the carbon fiber dome along the first cutting direction to form the first long side and the second long side of the carbon fiber dome.

S305, cutting the carbon fiber dome along a second cutting direction to form a first short side and a second short side of the carbon fiber dome.

The difference between this embodiment and embodiment 1 is that in step S302, the carbon fiber dome obtained by curing is provided with a foamed material layer, and one or more layers of carbon fiber unidirectional tapes are laminated on the upper surface and/or the lower surface of the foamed material layer. Prepreg. In this embodiment, the thickness of the cured carbon fiber unidirectional tape prepreg is 5 μm-100 μm; the mass fraction of the prepreg resin in the cured carbon fiber unidirectional tape prepreg is 10% to 55%. The thickness of the carbon fiber dome obtained in this embodiment is 20 μm to 2000 μm, preferably 80 μm to 200 μm.

In this embodiment, the foamed material layer contains a large number of fine bubbles or pores, and the average pore diameter of the bubbles or pores is 20 μm or less. In an optional embodiment, the pores in the foamed material layer have a pore diameter of 0.001 μm to 20 μm.

In this embodiment, the foamed material layer includes polyethylene terephthalate (PET), polymethacrylimide (PMI), polyphenylene sulfide (PPS), polyimide ( One or more materials among PI) and polypropylene (PP), select according to the required acoustic vibration range and force range during use. The foamed material layer of this embodiment is a polymer foamed body formed by foaming and molding the above-mentioned polymer material. The foamed material layer contains a large number of fine bubbles or pores, and the average pore diameter of the bubbles or pores is 20 μm. the following. For example, the foamed material layer may be foamed PET, foamed PMI, foamed PI, foamed PP, or foamed PPS.

For other parts that are the same as in Example 1, refer to the above for details.

The above are only the implementation manners of this application. It should be pointed out here that for those of ordinary skill in the art, improvements can be made without departing from the creative concept of this application, but these all belong to this application. The scope of protection.

Claims

A method for manufacturing a carbon fiber dome, characterized in that, in the process of cutting the carbon fiber dome into a predetermined shape, the carbon fiber dome is cut along a cutting direction that is at an angle with the extending direction of the carbon fiber. Cutting.
The manufacturing method according to claim 1, wherein the angle between the cutting direction and the extending direction of the carbon fiber is 5° to 85°.
The manufacturing method according to claim 1 or 2, wherein the cutting is laser cutting, edge trimming die cutting, or die cutting machine die cutting.
The manufacturing method according to claim 1, wherein the manufacturing method further comprises:

The carbon fiber unidirectional tape is pre-impregnated with prepreg resin to obtain the prepreg carbon fiber unidirectional tape;

One layer of the pre-impregnated carbon fiber unidirectional tape is cured, or at least two layers of the pre-impregnated carbon fiber unidirectional tape are bonded to each other and then cured to obtain a carbon fiber dome. The angle between the fiber directions of the two layers of the carbon fiber unidirectional belt is 0°-90°.
The manufacturing method according to claim 4, wherein the number of layers of the carbon fiber unidirectional tape prepreg in the carbon fiber dome is 1 to 20 layers.
The manufacturing method according to claim 1, wherein the manufacturing method further comprises:

The carbon fiber unidirectional tape is pre-impregnated with a prepreg resin to obtain a pre-impregnated carbon fiber unidirectional tape;

One or more layers of the pre-impregnated carbon fiber unidirectional tape are pasted on the upper surface and/or lower surface of the foamed material layer and then cured to obtain a carbon fiber dome. The fiber direction included angle of the unidirectional belt is 0°～90°.
The manufacturing method according to any one of claims 4 to 6, wherein the manufacturing method comprises:

The carbon fiber dome is cut along a first cutting direction to form the first long side and the second long side of the carbon fiber dome, wherein the first cutting direction is the same as each layer of carbon fiber unidirectional tape prepreg The extending directions of the medium carbon fibers are all at an angle;

The carbon fiber dome is cut along a second cutting direction to form a first short side and a second short side of the carbon fiber dome, wherein the second cutting direction is perpendicular to the first cutting direction, so The second cutting direction and the extending direction of the carbon fibers in each layer of the carbon fiber unidirectional tape prepreg are at an angle.
The manufacturing method according to any one of claims 4 to 6, wherein the mass fraction of the prepreg resin in the carbon fiber unidirectional tape prepreg is 10% to 55%.
The manufacturing method according to claim 6, wherein the foamed material layer comprises polyethylene terephthalate, polymethacrylimide, polyimide, polypropylene, and polyphenylene sulfide. One or more of ethers.
The manufacturing method according to claim 7, wherein the thickness of the carbon fiber dome is 80 μm to 200 μm.