TWI598215B - Producing method of integrated multi-curved surface structure - Google Patents

Description

Method for manufacturing integrally formed multi-curved structure

A manufacturing method, in particular, a method of manufacturing an integrally formed multi-curved structure formed of a core-sheath type fiber.

There are quite a variety of molding methods for composite fiber materials such as prepreg, such as hand lamination (hand lay-up), wrap molding, compression molding or vacuum molding.

The hand lamination method is to apply a resin to the surface of the model, lay a fiber cloth on the resin layer, and then apply a resin layer, and laminate the resin layer, the fiber layer, and the resin layer to a predetermined thickness, and then cure the resin. forming. The disadvantage of the hand lamination method is that the fiber cloth needs to be manually pieced together, the method is time-consuming, and the weaving pattern between each piece of fiber cloth is discontinuous, the appearance is less beautiful, and the resin needs to be formed and solidified immediately after coating, otherwise the resin will oxidize. , affecting the nature of the product.

The winding forming method is formed by winding a bundle of fiber yarns on a rotating mandrel with a specific winding tension. The disadvantage is that an object having a too large bending angle or having a plurality of curved curved surfaces cannot be produced, and the manufacturing process needs to be resistant to winding. The high quality mandrel of tension has a high manufacturing cost.

Molding or vacuum forming is to directly press a flat fiber cloth or fiberboard into a preset shape by hot pressing and vacuum forming, and the disadvantage is that the fiber cloth is large when forming a structure with a large bending angle or an object having a plurality of curved surfaces. The deformation of the angle or the excessive bending causes the yarn woven pattern to be displaced, deformed, and the wall thickness is thinned, and the yarn is even broken at the bend to cause flaws.

In order to solve the above various limitations of the composite fiber material molding method, the present invention provides a method for manufacturing an integrally formed multi-curved structure, comprising: a weaving preforming step: forming a core-sheath fiber into a preformed preformed structure in a braided manner, The contour and the size of the preformed structure correspond to the contour and size of the multi-curved structure. The core-sheath type fiber comprises a base material and a reinforcing material, and the base material covers the reinforcing material to form the core-sheath type fiber. The melting point of the reinforcing material is higher than the base material; and the curing forming step: curing the preformed structure by using a mold having a contour and a size corresponding to the multi-curved structure, and the base material is melted and bonded at a high temperature in the process. Curing is formed into the integrally formed multi-curved structure.

Wherein, between the weaving preforming step and the curing forming step, a predetermined step is further applied to melt or bond a part or a portion of the matrix material of the preformed structure.

Wherein, the predetermined step is to melt-bond the part or part of the base material of the preform structure by infrared heating.

Wherein, the base material is a thermoplastic resin comprising polyethylene, polypropylene, polyamine, polyamine, thermoplastic polyurethane, polymethacrylic acid, further comprising low molecular weight polyethylene, low density polyethylene, copolymerization Polypropylene, amorphous copolyester, low crystalline polyethylene terephthalate, dextran polylactic acid or low melting polyamide 66.

Wherein, the reinforcing material comprises ultra high molecular weight polyethylene, homopolypropylene, polyethylene terephthalate, L-polylactic acid, high melting polyamide 66, carbon fiber or glass fiber.

Wherein, the curing molding step is using hot press curing or vacuum forming.

As can be seen from the above description, the present invention has the following advantages:

1. The core-sheath fiber of the present invention can be integrally formed by mechanical weaving as compared with the existing hand lamination method, which requires labor-intensive one-piece resin-bonded fiber cloth and discontinuous weaving pattern of the finished product. The molding structure not only does not require additional coating resin adhesion, but also saves labor, and the finished product has a continuous weaving pattern and is relatively beautiful.

2. Compared with the existing winding forming method, the knitting method of the present invention can be directly formed by core-sheath type fiber braiding, or mechanically braided to reduce the cost of the core mold equipment; The lamination method requires a cumbersome processing process of manual bonding. In addition to reducing and reducing labor and labor costs, the present invention can even replace manual processing with an automated processing process.

3. The invention utilizes the pre-processing step of the woven preform to reduce the fabric of the object having a multi-curved structure, compared with the method of directly molding or vacuum forming the flat fiber cloth, thereby reducing the fiber cloth during molding or vacuum forming. The shape variable, the fiber cloth is less prone to cracking, and the structural strength of the high curvature turning point can be strengthened.

Referring to FIG. 1 to FIG. 2, a first preferred embodiment of the present invention is a method for manufacturing an integrally formed multi-curved helmet 10, the steps of which include:

Step 1 Weaving Preform: A core-sheath fiber 11 is integrally or mechanically knitted to form an integrally formed helmet pre-form 10A having a contour and size corresponding to the helmet 10. The aforementioned so-called contour or size correspondence means that the helmet preform structure 10A is similar to, similar to, or identical in contour and size to the helmet 10.

Referring to FIG. 2, the core-sheath type fiber 11 described in this embodiment is formed by coating a reinforcing material 112 with a base material 111. The melting temperature of the reinforcing material 112 is higher than the melting temperature of the base material 111. The melting temperature of the reinforcing material 112 and the base material 111 forms a working interval for heating and solidifying molding, sufficient to melt the base material 111 to uniformly coat the reinforcing material 112 but make the reinforcing material 112 still maintains the fiber state. The base material 111 is not limited, and is preferably a thermoplastic resin such as polyethylene (PE), polypropylene (PP), polyamine (PA), polyamine (Nylon), thermoplastic polyurethane (TPU), Polymethacrylic acid (PMMA), etc., further, such as low molecular weight polyethylene (LMWPE), low density polyethylene (LDPE), copolymerized polypropylene (CORA-PP), amorphous copolyester (PETG), low Crystalline polyethylene terephthalate (PET), dextran polylactic acid (PLA) or low melting polyamide 66 (Nylon 66); and the reinforcing material 112 is preferably ultra high molecular weight polyethylene (UHMWPE), both Polypropylene (PP), polyethylene terephthalate (PET), L-polylactic acid (PLA), high melting polyamide 66 (Nylon 66), carbon fiber or Glass fiber.

The core-sheath type fiber 11 is selected from the base material 111 and the material of the reinforcing material 112 to form a self-reinforced fiber. The self-reinforced fiber means that the base material 111 and the reinforcing material 112 are both For example, a polymer material of the same chemical composition may be used. For example, the base material 111 may be selected from a copolymerized polypropylene, and the reinforcing material 112 may be used to select a homopolypropylene to form a so-called self-reinforced fiber.

Step 2: Forming a hard hat mold 20, the inner surface of the helmet mold 20 has a cavity 21, the contour and size of the cavity 21 corresponding to the helmet 10, and the aforementioned safety helmet preform structure 10A is utilized. The cavity 21 in the helmet mold 20 is solidified into the helmet 10, preferably by hot press curing or vacuum forming.

The process temperature of the solidification molding in this step is higher than the melting point of the base material 111, but lower than the melting point of the reinforcing material 112. During the solidification molding process, the base material 111 of the outer layer of the core-sheath type fiber 11 is melted and cured. Formed as the helmet 10.

The purpose of the present invention is to use the core-sheath type fiber 11 to woven the helmet preform structure 10A because the outer portion of each of the core-sheath fibers 11 is coated with a melt-adhesive and solidified molding at a high temperature. The base material 111, when solidified and formed, the base material 111 between the fiber and the fiber is melted and bonded, so that the overall structure of the molding is tighter, the structural rigidity is better, and the resin adhesive layer can be formed without additional coating. The general prepreg can be improved, and the defects of delamination of the resin layer and the woven fabric layer or the peeling of the fibers are liable to occur at the time of solidification molding. And the woven pre-formed structure 10A has a continuous weaving pattern, and the appearance is more beautiful.

In this embodiment, between the weaving preforming step of step 1 and the curing forming step of step 2, a predetermined type of step may be further applied, because the helmet pre-formed structure 10A after the weaving preforming step may be due to the substrate. The material 111 has not been melt-bonded and fixed, and the overall structure exhibits a slight soft collapse condition. In order to avoid affecting the subsequent curing molding step, the base material 111 may be partially or partially bonded by heating means such as infrared rays to make the safety. The cap preform structure 10A can be slightly cured, fixed, and maintained in a preset multi-curved structure state to facilitate the implementation of the curing molding step.

Referring to FIG. 3, a second preferred embodiment of the present invention is a method of manufacturing a one-piece multi-curved luggage case 30, such as a generally commercially available cuboid case having four corners with high angle bend angles. The step of the second preferred embodiment of the present invention is the same as the first preferred embodiment of the present invention. The core-sheath type fiber 11 is first woven into a trunk pre-corresponding to the outline and size of the trunk 30 by the step of weaving preforming. The molding structure is formed into the luggage case 30 by the step of solidifying the luggage preform structure.

The purpose of the invention is to weave the core-sheath fiber 11 into a preformed structure before curing, in order to improve the general planar fiber cloth tends to be formed into a high-curvature structure in the step of molding and curing. The problem that the fiber cloth is damaged due to the curvature and the deformation amount is too large. Since the present invention first ties the core-sheath type fiber 11 to a structural shape close to the high bending angle, the bending of the fiber cloth during solidification molding or The shape variable is shaped relative to the fiber cloth directly in the plane, and the invention can reduce the problem of the fiber cloth being damaged in the high bending angle region, and the reinforcement of each part is more uniform. The invention can further utilize the advantages of the weaving process, adaptively formulate structures of different thicknesses, and can be thicker for regions with high curvature to reinforce structural strength.

The above is only the embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modifications or changes made in accordance with the embodiments of the present invention and the scope of the patent application are still within the scope of the present invention. .

10‧‧‧Safety helmet

10A‧‧‧Safety cap preformed structure

11‧‧‧core sheath fiber

111‧‧‧Base material

112‧‧‧Enhanced materials

20‧‧‧Safety helmet mould

21‧‧‧ cavity

30‧‧‧Luggage compartment

1 is a schematic view showing a manufacturing process of a first preferred embodiment of the present invention. 2 is a schematic cross-sectional view of a core-sheath fiber of the present invention. Figure 3 is a schematic view of a second preferred embodiment of the present invention.

10‧‧‧Safety helmet

10A‧‧‧Safety cap preformed structure

11‧‧‧core sheath fiber

20‧‧‧Safety helmet mould

21‧‧‧ cavity

Claims (8)

The manufacturing method of the integrally formed multi-curved structure comprises the steps of: weaving a preforming step: forming a core-sheath fiber into a preformed structure in a three-dimensional weaving manner, and the contour and size of the preformed structure are integrally formed. The contour and size of the multi-curved structure, the preformed structure comprising at least one region of high curvature, the core-sheath type fiber comprising a base material and a reinforcing material, the base material coating the reinforcing material to form the core-sheath fiber, the reinforcement The melting point of the material is higher than the base material; and the curing forming step: curing the preformed structure by using a mold having a contour and a size corresponding to the multi-curved structure, wherein the base material is higher than the melting point temperature of the base material And below the melting point temperature of the reinforcing material, it will be melt-bonded and then solidified into the integrally formed multi-curved structure. For example, in the manufacturing method of the body-formed multi-curved structure of the first aspect of the patent application, between the weaving preforming step and the curing forming step, a predetermined step is further applied to make the substrate partially or partially of the preformed structure. The material is melt bonded. The method for manufacturing a body-formed multi-curved structure according to the second aspect of the patent application, wherein the predetermined step is to melt-bond the part or a portion of the base material of the preform structure by infrared heating. A method of producing an integrally formed multi-curved structure according to claim 1 or 2 or 3, wherein the base material is a thermoplastic resin. A method for manufacturing a multi-curved structure of a body shape according to claim 1 or 2 or 3, the reinforcing material comprising ultra high molecular weight polyethylene, homopolypropylene, polyethylene terephthalate, L-polylactic acid, high Melting point polyamide 66, carbon fiber or glass fiber. A method for producing a body-formed multi-curved structure according to claim 4, wherein the base material comprises polyethylene, polypropylene, polyamine, polyamine, thermoplastic polyurethane, polymethacrylic acid. The manufacturing method of the multi-curved structure of the body shape according to the fourth item of the patent application, the base material comprises low molecular weight polyethylene, low density polyethylene, copolymerized polypropylene, amorphous copolyester, low crystalline polyparaphenylene Ethylene formate, dextran polylactic acid or low melting polyamide 66. The manufacturing method of the multi-curved structure of one of the first or second or third aspects of the patent application is the use of hot press curing or vacuum forming.