CN102049883A - Fiber laminated body structure with fabric touch and preparation method thereof - Google Patents
Fiber laminated body structure with fabric touch and preparation method thereof Download PDFInfo
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Abstract
Description
技术领域technical field
本发明涉及一种连续性强化纤维积层体,特别涉及一种具织物触感的纤维积层体结构及其制备方法,简化制程,且使产品更为轻薄,并能提升其强度,同时满足外观及触感的设计需求。The present invention relates to a continuous reinforced fiber laminate, in particular to a fiber laminate structure with fabric touch and its preparation method, which simplifies the manufacturing process, makes the product lighter and thinner, improves its strength and satisfies the appearance and tactile design requirements.
背景技术Background technique
随着科技的进步,电脑、行动电话、音响、显示器、个人数码助理等个人设备或装置的外部壳体,由早期的厚重的金属演变成轻薄的塑胶类制品,再于塑胶制的壳体表面利用各种镀覆或涂覆或绘饰等表面处理技术形成各种仿真外观与触感,如金属的亮冷感、皮革外观、木纹外观等,以满足人们追求个人特色的需求。With the advancement of science and technology, the external casings of personal equipment or devices such as computers, mobile phones, audio, monitors, and personal digital assistants have evolved from early heavy metals to light and thin plastic products, and then on the surface of plastic casings Use various surface treatment technologies such as plating, coating or painting to form various simulated appearances and touches, such as bright and cool metal, leather appearance, wood grain appearance, etc., to meet people's needs for personal characteristics.
因此,塑胶材料上涂上具有柔软触感的材料,用于人手经常会接触的产品,是公知的技术。早期为了使塑胶成型品或金属成型品的表面具有柔软的触感(例如,麂皮般的柔顺触感),则直接在成型品的外表面喷涂一层仿麂皮的涂层材料。日本特开平2-41243专利号中,即公开以色素粒子和电离辐射固化树脂,将材料喷涂于膜材上,产生良好的效果,即俗称的装饰板。此技术需电离辐射固化树脂组成,须照射电子束等,复杂且量产性并不理想。另日本特开平59-202830号专利,皆提出了利用射出成型技术,将板材制作成装饰板,产生具有柔软触感的表面。但在将其粘着于成型件表面时,常因成型件的曲线,造成界面搭接不良的结果。由上述的说明可知,受到异性材料的结合性不佳的影响,传统上这些装饰用的壳体存在有强度不足的问题,且即便结合不同触感或外观的材料,也存在有搭接不良的状况,再者于形成的制程上极为复杂,无形间也会增加其制造成本。Therefore, it is a known technology to coat plastic materials with soft-touch materials for products that are often touched by human hands. In the early days, in order to make the surface of the plastic molded product or the metal molded product have a soft touch (for example, suede-like supple touch), a layer of suede-like coating material is directly sprayed on the outer surface of the molded product. In Japanese Patent Application Laid-Open No. 2-41243, it is disclosed that pigment particles and ionizing radiation curing resin are used to spray the material on the film material to produce a good effect, which is commonly known as a decorative board. This technology needs to be composed of ionizing radiation-curable resin, and must be irradiated with electron beams, etc., which is complicated and not ideal for mass production. In addition, Japanese Patent Application Laid-Open No. 59-202830 proposes to use injection molding technology to make the board into a decorative board to produce a soft-touch surface. However, when it is adhered to the surface of the molded part, it is often caused by the curve of the molded part, resulting in poor interface overlap. From the above description, it can be seen that due to the poor bonding of heterosexual materials, traditionally these decorative shells have insufficient strength, and even if materials with different tactility or appearance are combined, there is also a situation of poor lap joints. , Moreover, the manufacturing process is extremely complicated, which will also increase the manufacturing cost invisibly.
在信息科技【Information Technology,IT】产品发展迅速需求下,业界无不开始追求更具耐冲击力、防电磁波且可被回收处理再利用并减少石化树脂用量的材料,以期符合全球的环保要求以及相关产业的需求。目前,连续性强化纤维积层业界所使用的材料有碳纤维【Carbon Fiber】、玻璃强化纤维【GlassFiber】、聚酯纤维【Polyester】及芳香族聚酰胺类纤维【Kevlar】等,而连续性强化纤维一般是具有连续性强化纤维,经热固性树脂【如Epoxy】的预浸处理,使得热固性树脂包覆纤维表面,人工将含浸热固性树脂未熟化【curing】的连续性强化纤维积层铺陈在模具内,再由适当机械装置加热、抽真空熟化【curing】成固定形状或将纤维积层在模具内热压塑型,加热使热固性树脂熟化,熟化的热固性塑胶可紧紧的与纤维表面结合,可利用热固性塑胶与纤维间的界面吸收外来的冲击力能量,进而形成高耐冲击力的结构。但是,热固性塑胶也是一种无法重复回收使用【Non-recyclable】的树脂,且塑型成品表面凹陷,不仅造成外观缺失,也带来结构强度影响之虑。为改善上述缺陷,塑型成品的凹陷部位需经补土涂装、打抛光才能达到外观要求,不仅旷时费工,打抛光造成的粉尘也容易造成污染,需要大量人工成本却又难以大量生产。为此申请人曾开发一种公告M362111号的「连续性强化纤维积层体结构」,以解决上述现有技术的所有缺点。Under the rapid development of information technology [Information Technology, IT] products, the industry has begun to pursue materials that are more impact-resistant, anti-electromagnetic, and can be recycled and reused to reduce the amount of petrochemical resins, in order to meet global environmental protection requirements and related industry needs. At present, the materials used in the continuous reinforced fiber lamination industry include carbon fiber [Carbon Fiber], glass reinforced fiber [GlassFiber], polyester fiber [Polyester] and aramid fiber [Kevlar], etc., and continuous reinforced fiber Generally, it has continuous reinforcing fibers, which are pre-impregnated with thermosetting resins [such as Epoxy], so that the thermosetting resins cover the surface of the fibers, and the continuous reinforcing fibers impregnated with thermosetting resins and uncured [curing] are artificially laid out in the mold. Then, it is heated by a suitable mechanical device, vacuumed and cured into a fixed shape, or the fibers are laminated in the mold for thermocompression molding, and the thermosetting resin is cured by heating. The cured thermosetting plastic can be tightly combined with the surface of the fiber, which can be used The interface between thermosetting plastic and fiber absorbs external impact energy, thereby forming a structure with high impact resistance. However, thermosetting plastic is also a kind of resin that cannot be recycled repeatedly [Non-recyclable], and the surface of the molded product is dented, which not only causes loss of appearance, but also brings about the impact of structural strength. In order to improve the above-mentioned defects, the concave parts of the molded products need to be filled with soil and polished to meet the appearance requirements. Not only is it time-consuming and labor-intensive, but the dust caused by polishing is also likely to cause pollution, requiring a lot of labor costs but difficult to produce in large quantities. . For this reason, the applicant has developed a "continuous reinforced fiber laminate structure" in the announcement No. M362111 to solve all the shortcomings of the above-mentioned prior art.
再者,目前业界运用织品在产品设计上,多半是将织品至于模具内,再用塑胶射出其基材,所以塑胶为其主要强度结构设计,故在设计上无法同时兼顾轻,薄及强度和刚性,且织品须结合另件,才能使之与塑胶能结合,因此无论是在表达个人特色的需求上,或是在实际的感官上,都不足以令人感到满意,有待进一步的改良。Furthermore, currently the industry uses fabrics in product design, most of them put the fabrics in the mold, and then use plastic to inject the base material. Therefore, plastic is the main strength structure design, so it is impossible to take into account lightness, thinness, strength and strength in the design. Rigidity, and the fabric must be combined with other parts to make it combined with plastic, so it is not satisfactory in terms of expressing personal characteristics or in actual sense, and needs further improvement.
发明内容Contents of the invention
本发明人针对上述现有制程复杂及无法提供织物触感的现况深入探讨,并藉由多年从事相关产业的研发与制造经验,积极寻求解决之道,经不断努力的研究与试验,终于成功的开发出一种具织物触感的纤维积层体结构及其制备方法,以解决现有技术制程复杂及结构强度不佳的问题。The present inventor has made an in-depth discussion on the current situation that the above-mentioned existing manufacturing process is complex and unable to provide fabric tactility, and through years of experience in research and development and manufacturing in related industries, he actively seeks a solution. After continuous efforts in research and testing, he finally succeeded A fiber laminate structure with fabric touch and its preparation method are developed to solve the problems of complicated manufacturing process and poor structural strength in the prior art.
本发明的主要目的在提供一种具织物触感的纤维积层体结构的制备方法,首先,制备织物面材;接着,制备连续性纤维层;之后,二者再经过烘烤、堆叠、热压成型,模内射出成型的步骤,而形成表面具织物触感的纤维积层体结构,使其保有织品外观及触感,并能增强结构强度。The main purpose of the present invention is to provide a method for preparing a fiber laminate structure with a fabric touch. First, prepare a fabric surface material; then, prepare a continuous fiber layer; after that, the two are baked, stacked, and hot-pressed Molding, the step of in-mold injection molding, to form a fiber laminate structure with a fabric-like feel on the surface, so that it retains the appearance and feel of the fabric, and can enhance the structural strength.
本发明主要通过下述的技术手段,来具体实现上述目的,制备方法包含有:The present invention mainly realizes the above-mentioned purpose through the following technical means, and the preparation method includes:
一制备织物面材的步骤,以半含浸或涂布方式于具织物触感的织物面材表面形成一第一热塑性树脂层;A step of preparing the fabric surface material, forming a first thermoplastic resin layer on the surface of the fabric surface material with fabric touch by semi-impregnating or coating;
一制备连续性纤维层的步骤,以含浸方式于连续性纤维或纤维布表面形成一第一热塑性树脂层,形成含浸连续性纤维层;A step of preparing a continuous fiber layer, forming a first thermoplastic resin layer on the surface of the continuous fiber or fiber cloth by impregnation to form an impregnated continuous fiber layer;
一堆叠步骤,将单一或复数层含浸连续性纤维层连续性强化的纤维层以及所述织物面材堆叠,形成含浸堆叠层;A stacking step, stacking a single or multiple layers of impregnated continuous fiber layer continuous reinforced fiber layer and the fabric surface material to form an impregnated stacked layer;
一再胶化热压的步骤,以油压热压机在25℃~150℃下,对所述含浸堆叠层进行热压,形成一体的且表面仍保留所述织物面材表面触感的连续性强化纤维板材;In the step of gelling and hot pressing again, the impregnated stacked layer is hot-pressed at 25°C to 150°C with an oil pressure hot press to form a continuous reinforcement that is integrated and the surface still retains the tactile feel of the fabric surface material fiberboard;
一热压成型的步骤,将一具预定形状的模具加热至120℃~180℃,所述连续性强化纤维板材加热至180℃~230℃,进行模具热压处理后,冷却至50℃~70℃,所述连续性强化纤维板材被塑形成预先成型的表面具织物触感的连续性强化纤维积层体;A step of hot pressing, heating a mold with a predetermined shape to 120°C to 180°C, heating the continuous reinforced fiber sheet to 180°C to 230°C, and cooling to 50°C to 70°C after hot pressing of the mold °C, the continuous reinforcing fiber sheet is shaped into a preformed continuous reinforcing fiber laminate with a fabric-like surface;
一模内射出成型的步骤,是利用所述具预定形状的模具进行二次射出成型,而于模具内部的纤维积层体表面形成一第二热塑性树脂层。An in-mold injection molding step is to use the mold with a predetermined shape to perform secondary injection molding to form a second thermoplastic resin layer on the surface of the fiber laminate inside the mold.
作为优选,上述制备织物面材层的步骤中所用具织物触感的织物面材为纺织品、编织布、不织布、由天然或合成纤维制成的编织织物、由天然或合成材料制成的编织织物、竹薄片、木薄片或天然与合成皮革中的任意一种。Preferably, the fabric surface material with fabric touch used in the above step of preparing the fabric surface material layer is textiles, woven fabrics, non-woven fabrics, woven fabrics made of natural or synthetic fibers, woven fabrics made of natural or synthetic materials, Either bamboo veneer, wood veneer or natural and synthetic leather.
作为优选,上述制备织物面材层和制备连续性纤维层的步骤中的第一热塑性树脂层为丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚乙烯、丙烯腈-苯乙烯共聚物、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯、聚酰胺、聚对苯二甲酸乙丁二醇酯、聚醚醚酮或聚醚酰亚胺中的任意一种。Preferably, the first thermoplastic resin layer in the steps of preparing the fabric face material layer and the continuous fiber layer is acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyethylene, acrylonitrile - any of styrene copolymer, polymethyl methacrylate, polyethylene terephthalate, polyamide, polyethylene terephthalate, polyetheretherketone or polyetherimide A sort of.
进一步,上述制备织物面材层的步骤后增加一微胶化烘烤的步骤,是在60℃~80℃下进行烘烤,使所述含浸织物面材层的第一热塑性树脂层微胶化,形成连续性具织物触感的织物面材;上述制备连续性纤维层之后,也增加一微胶化烘烤的步骤,是在60℃~80℃下进行烘烤,使所述含浸的连续纤维层的第一热塑性树脂层微胶化,形成具连续性强化的纤维层。Further, after the above step of preparing the fabric surface material layer, add a step of microgelation baking, which is to bake at 60°C to 80°C to microgelize the first thermoplastic resin layer impregnated with the fabric surface material layer , to form a continuous fabric surface material with a fabric touch; after the above-mentioned preparation of the continuous fiber layer, a step of microgelation baking is also added, which is to bake at 60 ° C to 80 ° C, so that the impregnated continuous fibers The first thermoplastic resin layer of the layer is microgelled to form a continuous reinforced fiber layer.
作为优选,上述制备连续性纤维层的步骤中的连续性纤维或纤维布为碳纤维、玻璃纤维、石棉纤维、工程塑胶纤维或天然纤维中的任意一种。Preferably, the continuous fiber or fiber cloth in the step of preparing the continuous fiber layer is any one of carbon fiber, glass fiber, asbestos fiber, engineering plastic fiber or natural fiber.
上述再胶化热压的步骤后,进一步增加一裁切的步骤,将所述一体的且表面仍保留所述织物面材表面触感的连续性强化纤维板材进行裁切。After the above step of regelling and hot pressing, a cutting step is further added to cut the integral continuous reinforced fiber sheet whose surface still retains the surface feel of the fabric surface material.
上述热压成型的步骤后,进一步增加一修边处理的步骤,利用电脑数值控制或水刀的边缘进行细部的加工处理。After the above step of hot pressing, a step of trimming is further added, and the edge of the computer numerical control or water jet is used for detailed processing.
上述第二热塑性树脂层包含丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚乙烯、丙烯腈-苯乙烯共聚物、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯、聚酰胺、聚对苯二甲酸乙丁二醇酯、聚醚醚酮或聚醚酰亚胺中的任意一种。上述第二热塑性树脂层为上述任一树脂添加一填充材料而成的合成树脂,其中填充材料包括滑石粉、碳纤维以及玻璃纤维中中的任意一种。The second thermoplastic resin layer includes acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyethylene, acrylonitrile-styrene copolymer, polymethyl methacrylate, polyterephthalic acid Any of glycol ester, polyamide, polyethylene terephthalate, polyether ether ketone, or polyetherimide. The above-mentioned second thermoplastic resin layer is a synthetic resin formed by adding a filler to any of the above-mentioned resins, wherein the filler includes any one of talcum powder, carbon fiber and glass fiber.
本发明的另一目的在提供一种连续性强化纤维积层体结构,该结构具有复数个连续性强化纤维层与面材目标物,面材目标物可与连续性强化纤维积层体的第一热塑性树脂完全粘合,并可完全保留面材的触感,同时达到节省成本并提高产品的品质,避免结构强度的疑虑。Another object of the present invention is to provide a continuous reinforced fiber laminate structure, which has a plurality of continuous reinforced fiber layers and a surface material object, and the surface material object can be combined with the first layer of the continuous reinforced fiber laminate. A thermoplastic resin is fully bonded and can completely retain the touch of the surface material, while saving costs and improving product quality, avoiding doubts about structural strength.
上述方法制备的具织物触感的纤维层体结构可当作机构外壳或保护罩,该纤维积层体结构包含有:The fiber layer structure with fabric touch prepared by the above method can be used as a mechanism shell or a protective cover, and the fiber layer structure includes:
一织物面材,以半含浸或涂布方式于具织物触感的织物面材表面形成一第一热塑性树脂层;A fabric surface material, forming a first thermoplastic resin layer on the surface of the fabric surface material with fabric touch by semi-impregnating or coating;
一连续性纤维层,以含浸方式于连续性纤维或纤维布的表面形成一第一热塑性树脂层,形成含浸连续性纤维层,所述含浸连续性纤维与所述织物面材经堆叠、再胶化热压和热压成型形成纤维积层体;A continuous fiber layer, forming a first thermoplastic resin layer on the surface of the continuous fiber or fiber cloth by impregnation to form an impregnated continuous fiber layer, the impregnated continuous fiber and the fabric surface material are stacked and then glued Hot pressing and hot pressing to form fiber laminates;
一第二热塑性树脂层,其射出成型于纤维积层体表面。A second thermoplastic resin layer is injection-molded on the surface of the fiber laminate.
作为优选,上述具织物触感的织物面材为纺织品、编织布、不织布、由天然或合成纤维制成的编织织物、由天然或合成材料制成的编织织物、竹薄片、木薄片、天然与合成皮革中的任意一种。Preferably, the above-mentioned fabric surface materials with fabric touch are textiles, woven fabrics, non-woven fabrics, woven fabrics made of natural or synthetic fibers, woven fabrics made of natural or synthetic materials, bamboo flakes, wood flakes, natural and synthetic Any kind of leather.
作为优选,上述织物面材层或连续性纤维层的第一热塑性树脂层为丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚乙烯、丙烯腈-苯乙烯共聚物、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯、聚酰胺、聚对苯二甲酸乙丁二醇酯、聚醚醚酮或聚醚酰亚胺中的任意一种。As preferably, the first thermoplastic resin layer of the above-mentioned fabric face material layer or continuous fiber layer is acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyethylene, acrylonitrile-styrene copolymer , polymethyl methacrylate, polyethylene terephthalate, polyamide, polyethylene terephthalate, polyetheretherketone or polyetherimide.
作为优选,上述连续性纤维层的纤维或纤维布为碳纤维、玻璃纤维、石棉纤维、工程塑胶纤维或天然纤维的中的任意一种。Preferably, the fibers or fiber cloth of the continuous fiber layer are any one of carbon fibers, glass fibers, asbestos fibers, engineering plastic fibers or natural fibers.
作为优选,上述第二热塑性树脂层包含丙烯腈-丁二烯-苯乙烯共聚物、聚苯乙烯、聚碳酸酯、聚乙烯、丙烯腈-苯乙烯共聚物、聚甲基丙烯酸甲酯、聚对苯二甲酸乙二醇酯、聚酰胺、聚对苯二甲酸乙丁二醇酯、聚醚醚酮或聚醚酰亚胺中的任意一种。上述第二热塑性树脂层为任一上述树脂添加一填充材料而成的合成树脂,其中填充材料包括滑石粉、碳纤维或玻璃纤维中的任意一种。Preferably, the above-mentioned second thermoplastic resin layer comprises acrylonitrile-butadiene-styrene copolymer, polystyrene, polycarbonate, polyethylene, acrylonitrile-styrene copolymer, polymethyl methacrylate, polyparaffin Any one of ethylene phthalate, polyamide, polyethylene terephthalate, polyetheretherketone, or polyetherimide. The above-mentioned second thermoplastic resin layer is a synthetic resin obtained by adding a filler to any of the above-mentioned resins, wherein the filler includes any one of talcum powder, carbon fiber or glass fiber.
本发明实现了下述有益效果:制备程序大幅简化,且使产品更为轻薄,不仅能提升其基本结构强度,并能使壳体表层产生织品的触感与外观,大幅增加产品的附加价值,进一步可增进产品的经济效益。The invention achieves the following beneficial effects: the preparation procedure is greatly simplified, and the product is lighter and thinner, which not only improves its basic structural strength, but also enables the surface layer of the shell to produce the texture and appearance of fabric, greatly increasing the added value of the product, and further Can enhance the economic benefits of the product.
附图说明Description of drawings
图1是本发明的表面具织物触感的连续性强化纤维积层体制造方法的流程图;Fig. 1 is the flowchart of the manufacturing method of the continuous reinforced fiber laminate with fabric touch on the surface of the present invention;
图2是为本发明的织物面材与连续性强化纤维层的剖面示意图;Fig. 2 is a schematic cross-sectional view of a fabric surface material and a continuous reinforcing fiber layer of the present invention;
图3是为本发明的具织物触感的连续性强化纤维层的剖面示意图。Fig. 3 is a schematic cross-sectional view of the continuous reinforcing fiber layer with fabric touch of the present invention.
图4是为本发明形成表面具织物触感的连续性强化纤维积层体的外观示意图。Fig. 4 is a schematic view of the appearance of a continuous reinforcing fiber laminate formed with a fabric-like surface according to the present invention.
图5是为本发明的具织物触感的纤维积层体结构的示意图。Fig. 5 is a schematic diagram of the structure of the fiber laminate with fabric touch of the present invention.
上述附图中标号说明:Explanation of the numbers in the above-mentioned accompanying drawings:
S10 制备织物面材;S10 prepare fabric surface material;
S15 微胶化烘烤;S15 microgelation baking;
S20 制备连续性纤维层;S20 Prepare a continuous fiber layer;
S25 微胶化烘烤;S25 microgelation baking;
S30 堆叠;S30 stacking;
S40 再胶化热压;S40 regelation hot pressing;
S50 裁切;S50 cut;
S60 热压成型;S60 thermoforming;
S70 修边处理;S70 trimming treatment;
S80 模内射出成型;S80 In-mold injection molding;
10 织物面材; 11 第一热塑性树脂层;10 fabric facing material; 11 first thermoplastic resin layer;
20 纤维层; 21 第一热塑性树脂层;20 fiber layer; 21 first thermoplastic resin layer;
30 第二热塑性树脂层; 50 纤维积层体。30 second thermoplastic resin layer; 50 fiber laminate.
具体实施方式Detailed ways
本发明是一种具织物触感的纤维积层体结构及其制备方法,附图所示的本发明纤维积层体结构的具体实施例及其结构中,所有关于前与后、左与右、顶部与底部、上部与下部、以及水平与垂直的参考,仅用于方便进行描述,并非限制本发明,亦非将其结构限制于任何位置或空间方向。附图与说明书中所指定的尺寸,当可在本发明的保护范围内,根据本发明的具体实施例的设计与需求而进行变化。The present invention is a fiber laminate structure with fabric touch and its preparation method. In the specific embodiment of the fiber laminate structure of the present invention and its structure shown in the accompanying drawings, all about front and back, left and right, References to top and bottom, upper and lower, and horizontal and vertical are used for convenience of description only, and do not limit the invention, nor limit its structure to any position or spatial orientation. The dimensions specified in the drawings and the specification can be changed according to the design and requirements of the specific embodiments of the present invention within the protection scope of the present invention.
关于本发明具织物触感的纤维积层体结构的制备方法,如附图1所示,步骤包括:一制备织物面材S10、一制备连续性纤维层S20、一堆叠S30、一再胶化热压S40、一裁切S50、一热压成型S60、一修边处理S70及一模内射出成型S80步骤,形成一种表面具织物触感的连续性强化纤维积层体50;Regarding the preparation method of the fiber laminate structure with fabric touch of the present invention, as shown in Figure 1, the steps include: one preparation of fabric surface material S10, one preparation of continuous fiber layer S20, one stacking S30, one re-gelling hot pressing S40, a cutting S50, a thermoforming S60, a trimming S70 and an in-mold injection molding S80, forming a continuous reinforced
首先,由制备织物面材S10步骤开始,以半含浸或涂布方式于具织物触感的织物面材表面形成一第一热塑性树脂层11,其中织物面材选自但不局限于:任何种类的纺织品或类似纺织的材料,例如:编织布、不织布、以及由天然或合成纤维料制成的编织织物、由天然或合成材料制成的编织织物、竹薄片、木薄片、天然与合成皮革等片状材料中的任意一种,而第一热塑性树脂层11选自但不局限于:丙烯腈-丁二烯-苯乙烯共聚物【Acrylonitrile-Butadiene-Styrene,ABS】、聚苯乙烯【Polystyrene,PS】、聚碳酸酯【Polycarbonate,PC】、聚乙烯【Polyethylene,PE】、丙烯腈-苯乙烯共聚物【Acrylonitrile-Styrene,AS】、聚甲基丙烯酸甲酯【Polymethylmethacrylate,PMMA】、聚对苯二甲酸乙二醇酯【Polyethylene Terephthalate,PET】、聚酰胺【Polyamide,PA】、聚对苯二甲酸乙丁二醇酯【Polybothlene Terephthalate,PBT】、聚醚醚酮【Polyether EtherKetone,PEEK】以及聚醚酰亚胺【Polyetherimide,PEI】中的任意一种。制备织物面材S 10之后可增加一微胶化烘烤S 15的步骤,其是在60~80℃下进行烘烤,使织物面材10的第一热塑性树脂层11微胶化,各自形成连续性保留原材料触感的织物面材10;First, starting from the step of preparing the fabric surface material S10, a first
接着,进行制备连续性纤维层S20的步骤,以含浸方式于连续性纤维或纤维布表面形成一第一热塑性树脂层21,形成含浸连续性纤维层20,使得第一热塑性树脂层21完全填充连续性纤维层20内部的缝隙,并且包覆连续性纤维层20的整个表面。该含浸处理步骤的实施方式可藉滚轮带动卷筒状的连续性纤维布,以浸泡在装有第一热塑性树脂的处理槽中,并带离开该处理槽,使含浸连续性纤维布具有第一热塑性树脂,而形成连续性的纤维层20,参见附图2中连续性纤维层20。其中,连续性纤维层20的连续性纤维或纤维布选自但不局限于:碳纤维、玻璃纤维、石棉纤维、工程塑胶纤维以及天然纤维中的任意一种。而第一热塑性树脂层21选自但不局限于:丙烯腈-丁二烯-苯乙烯共聚物【Acrylonitrile-Butadiene-Styrene,ABS】、聚苯乙烯【Polystyrene,PS】、聚碳酸酯【Polycarbonate,PC】、聚乙烯【Polyethylene,PE】、丙烯腈-苯乙烯共聚物【Acrylonitrile-Styrene,AS】、聚甲基丙烯酸甲酯【Polymethylmethacrylate,PMMA】、聚对苯二甲酸乙二醇酯【Polyethylene Terephthalate,PET】、聚酰胺【Polyamide,PA】、聚对苯二甲酸乙丁二醇酯【Polybothlene Terephthalate,PBT】、聚醚醚酮【Polyether Ether Ketone,PEEK】以及聚醚酰亚胺【Polyetherimide,PEI】中的任意一种。制备连续性纤维层S20之后增加一微胶化烘烤S25的步骤,在60~80℃下进行烘烤,使含浸的连续纤维或纤维布的第一热塑性树脂层21微胶化,而形成具连续性强化的纤维层20;Next, carry out the step of preparing the continuous fiber layer S20, form a first
之后,进行堆叠S30的步骤,将单一或复数层连续性强化的纤维层20与织物面材10堆叠,而形成含浸堆叠层;Afterwards, perform the step of stacking S30, stacking a single or multiple layers of continuous reinforced
接着,进行再胶化热压S40步骤,以油压热压机在25℃~150℃下,对上述连续式堆叠的织物面材10与连续性纤维层20进行热压,使第一热塑性树脂层11和第一热塑性树脂层21渗入织物面材10与纤维层20内约20%~70%,且二者的第一热塑性树脂层11和第一热塑性树脂层21再胶化并完全融合,形成一体且表面仍保留原织物面材的表面触感的连续性强化纤维板材,如附图3所示;Next, carry out the step of regelatinization and hot pressing S40, using an oil pressure hot press at 25°C to 150°C to heat press the above-mentioned continuously stacked
接着,进行裁切S50的步骤,将经过上述再胶化热压S40的步骤成型的连续性强化纤维板材进行裁切,以产生适当尺寸大小的连续性强化纤维板材;Next, the step of cutting S50 is carried out, and the continuous reinforced fiber sheet formed by the step of regelling and hot pressing S40 is cut to produce a continuous reinforced fiber sheet of appropriate size;
而后,进入热压成型S60的步骤,将一具预定形状之模具加热至120℃~180℃,且上述适当尺寸大小的连续性强化纤维板材加热至180℃~230℃,以进行模具热压处理,且在模具内冷却至50℃~70℃,使平板状的具表面触感的连续性强化纤维板材被塑形成预先成型的表面具织物触感的连续性强化纤维积层体50,如附图4所示,具有所需的特定外观形状,约具有凹面、凸面、弯折、缺口、开口;Then, enter the step of hot press forming S60, heat a mold with a predetermined shape to 120°C-180°C, and heat the above-mentioned continuous reinforced fiber sheet of appropriate size to 180°C-230°C to perform mold hot-pressing treatment , and cooled to 50°C to 70°C in the mold, so that the flat continuous reinforcing fiber sheet material with a surface feel is molded into a preformed continuous reinforcing
之后,再进行修边处理S70的步骤,其利用电脑数值控制【ComputerNumerical Control,CNC】或水刀的边缘进行细部加工处理;After that, the step of trimming processing S70 is carried out, which uses computer numerical control [Computer Numerical Control, CNC] or water jet edge for detailed processing;
最后,进行模内射出成型S80的步骤,利用具预定形状的模具进行二次射出成型,而于模具内部的纤维积层体50表面形成一第二热塑性树脂层30,其中第二热塑性树脂层30包含丙烯腈-丁二烯-苯乙烯共聚物【Acrylonitrile-Butadiene-Styrene,AB S】、聚苯乙烯【Polystyrene,PS】、聚碳酸酯【Polycarbonate,PC】、聚乙烯【Polyethylene,PE】、丙烯腈-苯乙烯共聚物【Acrylonitrile-Styrene,AS】、聚甲基丙烯酸甲酯【Polymethylmethacrylate,PMMA】、聚对苯二甲酸乙二醇酯【Polyethylene Terephthalate,PET】、聚酰胺【Polyamide,PA】、聚对苯二甲酸乙丁二醇酯【Polybothlene Terephthalate,PBT】、聚醚醚酮【Polyether Ether Ketone,PEEK】或聚醚酰亚胺【Polyetherimide,PEI】中的任意一种。第二热塑性树脂层30为任一上述树脂添加一填充材料而成的合成树脂【Alloy Resin】,且其中填充材料包括滑石粉【Talc】、碳纤维【Carbon Fiber】或玻璃纤维【Glass Fiber】中的任意一种。进而使表面具织物触感的连续性强化纤维积层体50与第二热塑性树脂层30结合成一体的连续强化纤维积层体结构的成品。上述纤维积层体结构可当作机构外壳或保护罩,以提供保护并增加美观及更舒适的触感。Finally, perform the step of in-mold injection molding S80, use a mold with a predetermined shape to perform secondary injection molding, and form a second thermoplastic resin layer 30 on the surface of the
透过前述的设计,本发明不仅可简化制程,且该纤维积层体结构具有复数个连续性强化纤维层20与织物面材10,上述织物面材10可与连续性强化纤维层20的第一热塑性树脂层21完全粘合,并可完全保留面材的触感,同时达到节省成本并提高产品的品质,避免结构强度的疑虑。Through the aforementioned design, the present invention not only simplifies the manufacturing process, but also the fiber laminate structure has a plurality of continuous reinforcing
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例,本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换,均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。The above-mentioned embodiments are only preferred embodiments for fully illustrating the present invention, and the protection scope of the present invention is not limited thereto. Equivalent substitutions or transformations made by those skilled in the art on the basis of the present invention are all within the protection scope of the present invention. The protection scope of the present invention shall be determined by the claims.
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