TWI764221B - Composite material structure - Google Patents

Abstract

A composite material structure including a core substrate, a first carbon fiber layer and a second carbon fiber layer is provided. The core substrate includes a first area and a second area connected to the first area, wherein the first area has a first thickness and the second area has a second thickness smaller than the first thickness. The first carbon fiber layer is adhered to a side of the core substrate and extends from the first area to the second area. The second carbon fiber layer is adhered to another side of the core substrate and extends from the first area to the second area. The core substrate is located between the first carbon fiber layer and the second carbon fiber layer.

Description

composite structure

The present invention relates to a composite material, and in particular to a composite material structure.

With the changes in consumers' living and working patterns, portable electronic devices such as smart phones, tablet computers, e-book readers, and notebook computers have become mainstream in the current market. In order to improve the convenience of carrying and reduce the carrying burden, the portable electronic devices are all developing towards light weight. As the main component of the portable electronic device, the casing can not only be used for loading electronic components or display panels, but also has a protective effect.

Since the chassis accounts for a large proportion of the weight of the portable electronic device, developing a chassis with light weight and excellent mechanical strength is always an important issue for related manufacturers. Generally speaking, common casings include plastic casings, alloy casings and carbon fiber casings. The weight of carbon fiber casings is lighter than that of plastic casings and alloy casings, and the mechanical strength of carbon fiber casings is higher than that of plastic casings. And alloy casing is excellent, so the development of carbon fiber casing has gradually been paid attention to.

At present, the construction methods used for carbon fiber casings can be divided into thermosetting methods and thermoplastic methods. The thermoplastic method adopts injection molding technology and has a fast mass production speed, and is mainly used in the production of casings for portable electronic devices. However, in the process of injection molding, the infiltration of plastic into the core material often occurs, which in turn affects the weight and mechanical strength of the carbon fiber casing.

The present invention provides a composite material structure that is lightweight and excellent in mechanical strength.

The present invention provides a composite material structure, which includes a core material, a first carbon fiber layer and a second carbon fiber layer. The core material includes a first block and a second block connected to the first block, wherein the first block has a first thickness, and the second block has a second thickness smaller than the first thickness. The first carbon fiber layer is attached to one side of the core material and extends from the first block to the second block. The second carbon fiber layer is attached to the other side of the core material and extends from the first block to the second block. The core material is located between the first carbon fiber layer and the second carbon fiber layer.

In an embodiment of the present invention, the above-mentioned core material includes a core layer, a first adhesive layer and a second adhesive layer, and the core layer has a first surface and a second surface opposite to the first surface. The first adhesive layer is arranged on the first surface, and the second adhesive layer is arranged on the second surface. The first carbon fiber layer is attached to the first adhesive layer, and the second carbon fiber layer is attached to the second adhesive layer.

In an embodiment of the present invention, the above-mentioned core layer has a plurality of first holes in the first block and a plurality of second holes in the second block, and the diameters of the first holes are larger than those of the second holes The hole diameter.

In an embodiment of the present invention, the above-mentioned first holes are not communicated with each other, and the second holes are not communicated with each other.

In an embodiment of the present invention, the diameters of the first holes and the second holes are between 0.05 and 0.5 mm.

In an embodiment of the present invention, a first boundary line exists between the first carbon fiber layer and the first adhesive layer, and part of the first adhesive layer penetrates into part of the first hole and part of the second hole from the first surface to form The second boundary line, wherein the ratio of the length of the second boundary line to the length of the first boundary line is greater than 1.05.

In an embodiment of the present invention, the material of the above-mentioned core layer includes a compound of acrylonitrile and methacrylic acid, polymethacrylimide, polyvinyl chloride, polystyrene, polyurethane, acrylonitrile-styrene copolymer compound, polyetherimide, polypropylene, or a combination thereof.

In an embodiment of the present invention, the materials of the first adhesive layer and the second adhesive layer include polycaprolactone, polyether polyol, polyurethane or a combination thereof.

In an embodiment of the present invention, the thickness of the above-mentioned core layer ranges from 0.1 to 1.5 mm.

In an embodiment of the present invention, the density of the core layer is between 0.003 and 1 g/cm 3 .

In an embodiment of the present invention, the above-mentioned first carbon fiber layer is turned at the interface between the first block and the second block, and the height of the first carbon fiber layer in the first block is higher than that of the first carbon fiber The height of the layer within the second block.

In an embodiment of the present invention, the above-mentioned ratio of the first thickness to the second thickness is less than or equal to 15 and greater than 1.

In an embodiment of the present invention, the above-mentioned composite material structure further includes a plastic layer. The plastic layer covers at least a portion of the first carbon fiber layer located within the second block.

In an embodiment of the present invention, the length of the first block is greater than the length of the second block.

Based on the above, in the composite material structure of the present invention, the core material is divided into a first block and a second block surrounding the first block, wherein the thickness of the core material in the second block is smaller than that of the core material in the first block thickness in the block, and the density of the core material in the second block is greater than the density of the core material in the first block. Subsequently, in the process of injection molding, the second block with higher density can effectively prevent the plastic from infiltrating into the core material. Therefore, the composite structure is lightweight and excellent in mechanical strength.

In order to make the above-mentioned features and advantages of the present invention more obvious and easy to understand, the following embodiments are given and described in detail with the accompanying drawings as follows.

FIG. 1 is a schematic top view of a composite material structure according to an embodiment of the present invention. FIG. 2 is a partial enlarged cross-sectional schematic diagram of the composite material structure of FIG. 1 along the section line I-I. Please refer to FIG. 1 and FIG. 2 , in this embodiment, the composite material structure 100 can be applied to a carbon fiber chassis, wherein the composite material structure 100 includes a core material 110 , a first carbon fiber layer 120 and a second carbon fiber layer 130 , and the core material 110 is located between the first carbon fiber layer 120 and the second carbon fiber layer 130 . In other words, the first carbon fiber layer 120 and the second carbon fiber layer 130 are located on opposite sides of the core material 110 respectively.

The core material 110 includes a first block A1 and a second block A2 connected to the first block A1, wherein the second block A2 surrounds the first block A1, and the area of the first block A1 is larger than that of the second block A2 area. For example, the composite material structure 100 is placed on the X-Y plane in space. On the X-axis or the Y-axis, the length L1 of the first block A1 is greater than the length L2 of the second block A2.

On the other hand, the first block A1 of the core material 110 has a first thickness T1, and the second block A2 of the core material 110 has a second thickness T2 smaller than the first thickness T1. Further, the ratio of the first thickness T1 to the second thickness T2 is less than or equal to 15 and greater than 1.

For example, the thickness of the original core material is equal. After the lamination process, the core material 110 is divided into a first block A1 and a second block A2 surrounding the first block A1, wherein the core material 110 is in the second block A1. The thickness in the block A2 is smaller than the thickness of the core material 110 in the first block A1, and the density of the core material 110 in the second block A2 is greater than the density of the core material 110 in the first block A1. Subsequently, during the injection molding process, the second block A2 with higher density can effectively prevent the plastic from infiltrating into the core material 110 . Therefore, the composite material structure 100 is lightweight and excellent in mechanical strength.

Referring to FIG. 2 , the first carbon fiber layer 120 is attached to one side of the core material 110 and extends from the first area A1 to the second area A2 . The second carbon fiber layer 130 is attached to the other side of the core material 110 and extends from the first block A1 to the second block A2. Specifically, the core material 110 includes a core layer 111 , a first adhesive layer 112 and a second adhesive layer 113 , and the core layer 111 has a first surface 111 a and a second surface 111 b opposite to the first surface 111 a. The first adhesive layer 112 is disposed on the first surface 111a, and the second adhesive layer 113 is disposed on the second surface 111b. The first carbon fiber layer 120 is adhered to the first adhesive layer 112 , and the second carbon fiber layer 130 is adhered to the second adhesive layer 113 .

In this embodiment, the core layer 111 may be a polymer foam, preferably a closed-cell foam. Further, the material of the core layer 111 may include a compound of acrylonitrile and methacrylic acid, polymethacrylimide, polyvinyl chloride, polystyrene, polyurethane, acrylonitrile-styrene copolymer, polyether amide imine, polypropylene, or a combination thereof. On the other hand, the material of the first adhesive layer 112 and the second adhesive layer 113 may include polycaprolactone, polyether polyol, polyurethane or a combination thereof.

Further, the core layer 111 has a plurality of first holes 114 located in the first block A1 and a plurality of second holes 115 located in the second block A2, wherein the first holes 114 are not communicated with each other, and these The second holes 115 are not communicated with each other. That is to say, each first hole 114 is an independent and closed hole, and is not communicated with other first holes 114 , nor with any second hole 115 . On the other hand, each second hole 115 is an independent and closed hole, and is not communicated with other second holes 115 , nor is it communicated with any first hole 114 .

The hole diameters R1 of the first holes 114 are larger than the hole diameters R2 of the second holes 115 , wherein the hole diameters of the first holes 114 are different in size, and the diameters of the second holes 115 are different in size. Further, the smallest diameter of the first holes 114 is larger than the largest diameter of the second holes 115 , and the diameters R1 of the first holes 114 and the diameters R2 of the second holes 115 are between 0.05 and 0.5 mm.

For example, the original core layer has a plurality of cavities, but these cavities do not differ significantly in size from block to block. After the lamination process, the compression amount of the core layer 111 in the second block A2 is relatively large. Therefore, the holes located in the second block A2 form the second holes 115 with smaller diameters. Subsequently, during the injection molding process, the second holes 115 with smaller diameters can effectively prevent the plastic from infiltrating into the core layer 111 . Therefore, the composite material structure 100 is lightweight and excellent in mechanical strength.

In this embodiment, the thickness of the core layer 111 in the first block A1 is T3, and the thickness of the core layer 111 in the second block A2 is T4. The thickness T4 is smaller than the thickness T3, wherein the maximum thickness T3 may be 1.5 mm, and the minimum thickness T4 may be 0.1 mm, so the thickness of the core layer 111 is between 0.1 mm and 1.5 mm.

For example, the thickness of the original core layer is the same thickness. After the lamination process, the thickness of the core layer 111 in the second block A2 is smaller than the thickness of the core layer 111 in the first block A1, and the core layer 111 is in the second block A2. The density in the second block A2 is greater than the density of the core layer 111 in the first block A1. Subsequently, in the process of injection molding, the second block A2 with higher density can effectively prevent the plastic from infiltrating into the core layer 111 . Therefore, the composite material structure 100 is lightweight and excellent in mechanical strength. Further, the density of the core layer 111 ranges from 0.003 to 1 g/cm 3 , and the position with the highest density is located in the second block A2 .

Referring to FIG. 2 , in this embodiment, the first carbon fiber layer 120 is turned at the boundary 101 between the first block A1 and the second block A2 , and the first carbon fiber layer 120 is in the first block A1 The height is higher than the height of the first carbon fiber layer 120 in the second block A2. On the other hand, the second carbon fiber layer 130 extends smoothly, and the height of the second carbon fiber layer 130 in the first block A1 is equal to the height of the second carbon fiber layer 130 in the second block A2.

For example, a first boundary line S1 exists between the first carbon fiber layer 120 and the first adhesive layer 112 , and the first boundary line S1 falls on the upper surface of the first adhesive layer 112 . The lower surface of the first adhesive layer 112 is attached to the first surface 111a of the core layer 111 . During the process of thermocompression, part of the first adhesive layer 112 penetrates into part of the first hole 114 and part of the second hole from the first surface 111a 115 to form the second boundary line S2. The length of the second boundary line S2 is greater than the length of the first boundary line S1 , wherein the second boundary line S2 has bumps and depressions, and the ratio of the length of the second boundary line S2 to the length of the first boundary line S1 is greater than 1.05. Based on this, the first adhesive layer 112 and the core layer 111 can be tightly bonded together, and the first carbon fiber layer 120 can be closely attached to the core layer 111 through the first adhesive layer 112 .

Similarly, a third boundary line S3 exists between the second carbon fiber layer 130 and the second adhesive layer 113 , wherein the third boundary line S3 falls on the lower surface of the second adhesive layer 113 . The upper surface of the second adhesive layer 113 is attached to the second surface 111b of the core layer 111. During the thermocompression bonding process, part of the second adhesive layer 113 penetrates from the second surface 111b into part of the first hole 114 and part of the second hole 115 to form the fourth boundary line S4. The length of the fourth boundary line S4 is greater than the length of the third boundary line S3, wherein the fourth boundary line S4 has concavities and convexities, and the ratio of the length of the fourth boundary line S4 to the length of the third boundary line S3 is greater than 1.05. Based on this, the second adhesive layer 113 and the core layer 111 can be tightly bonded together, and the second carbon fiber layer 130 can be closely attached to the core layer 111 through the second adhesive layer 113 .

Specifically, the second boundary line S2 is a boundary line defined by part of the first cavity 114 and part of the second cavity 115 filled by the first adhesive layer 112 , and has concave-convex volts. In addition, the fourth boundary line S4 is a boundary line defined by a part of the first hole 114 and a part of the second hole 115 filled by the second adhesive layer 113 , and has concave-convex volts.

3 is a partial enlarged cross-sectional schematic diagram of a composite material structure according to another embodiment of the present invention. Referring to FIG. 3 , compared with the composite material structure 100 of the previous embodiment, the composite material structure 100A of the present embodiment further includes a plastic layer 140 a , wherein the plastic layer 140 a is formed on the second side of the core material 110 by injection molding technology. block A2, and the plastic layer 140a partially covers the first carbon fiber layer 120 located in the second block A2. Further, the location of the plastic layer 140a is close to the edge of the second block A2. On the other hand, the plastic layer 140 a also covers the edge of the core layer 111 , but the plastic layer 140 a does not penetrate into the core layer 111 .

4 is a partial enlarged cross-sectional schematic diagram of a composite material structure according to another embodiment of the present invention. Referring to FIG. 4 , compared with the composite material structure 100 of the previous embodiment, the composite material structure 100B of the present embodiment further includes a plastic layer 140b, wherein the plastic layer 140b is formed on the second side of the core material 110 by injection molding technology. block A2, and the plastic layer 140b completely covers the first carbon fiber layer 120 in the second block A2. On the other hand, the plastic layer 140b also covers the edge of the core layer 111, but the plastic layer 140b does not penetrate into the core layer 111.

To sum up, in the composite material structure of the present invention, the thickness of the core layer in the second block is smaller than the thickness of the core layer in the first block, and the density of the core layer in the second block is greater than that of the core layer Density within the first block. Subsequently, in the process of injection molding, the second block with higher density can effectively prevent the plastic from infiltrating into the core layer. Therefore, the composite structure is lightweight and excellent in mechanical strength. On the other hand, the holes located in the second block are second holes with smaller diameters, and subsequently, in the process of injection molding, the second holes with smaller diameters can effectively prevent the plastic from infiltrating into the core layer.

Although the present invention has been disclosed as above with examples, it is not intended to limit the present invention. Anyone with ordinary knowledge in the technical field can make some changes and modifications without departing from the spirit and scope of the present invention. The protection scope of the present invention shall be determined by the scope of the appended patent application.

100, 100A, 100B: Composite Structures 101: Junction 110: Core material 111: Core layer 111a: first surface 111b: second surface 112: The first adhesive layer 113: Second adhesive layer 114: The first hole 115: The second hole 120: First carbon fiber layer 130: Second carbon fiber layer 140a, 140b: plastic layer A1: The first block A2: Second block I-I: Section Line L1, L2: length R1, R2: aperture S1: First Junction S2: Second Junction S3: Third Junction S4: Fourth Junction T1: first thickness T2: Second thickness T3, T4: Thickness

FIG. 1 is a schematic top view of a composite material structure according to an embodiment of the present invention. FIG. 2 is a partial enlarged cross-sectional schematic diagram of the composite material structure of FIG. 1 along the section line I-I. 3 is a partial enlarged cross-sectional schematic diagram of a composite material structure according to another embodiment of the present invention. 4 is a partial enlarged cross-sectional schematic diagram of a composite material structure according to another embodiment of the present invention.

100: Composite Structures

101: Junction

110: Core material

111: Core layer

111a: first surface

111b: second surface

112: The first adhesive layer

113: Second adhesive layer

114: The first hole

115: The second hole

120: First carbon fiber layer

130: Second carbon fiber layer

A1: The first block

A2: Second block

R1, R2: aperture

S1: First Junction

S2: Second Junction

S3: Third Junction

S4: Fourth Junction

T1: first thickness

T2: Second thickness

T3, T4: Thickness

Claims (13)

A composite material structure, comprising: a core material, including a first block and a second block connected to the first block, wherein the first block has a first thickness, and the second block has a thickness smaller than the first block a second thickness of the thickness; a first carbon fiber layer attached to one side of the core material and extending from the first block to the second block; and a second carbon fiber layer attached to the other side of the core material one side, and extends from the first block to the second block, the core material is located between the first carbon fiber layer and the second carbon fiber layer, wherein the core material includes a core layer and a first adhesive layer, and The core layer has a first surface and a second surface opposite to the first surface, the first adhesive layer is disposed on the first surface, and the second adhesive layer is disposed on the second surface, the first carbon fiber The layer is attached to the first adhesive layer, and the core layer has a plurality of first holes in the first block and a plurality of second holes in the second block, the first carbon fiber layer and the A first boundary line exists between the first adhesive layers, and a part of the first adhesive layer penetrates into a part of the first holes and a part of the second holes from the first surface to form a second boundary line, wherein the second boundary The ratio of the length of the line to the length of the first boundary line is greater than 1.05. The composite material structure of claim 1, wherein the core material further comprises a second adhesive layer, and the second adhesive layer is disposed on the second surface, and the second carbon fiber layer is adhered to the second adhesive layer. The composite material structure of claim 1, wherein the pore diameters of the first pores are larger than the pore diameters of the second pores. The composite material structure as claimed in claim 1, wherein the first pores are not communicated with each other, and the second pores are not communicated with each other. The composite material structure of claim 1, wherein the diameters of the first holes and the second holes are between 0.05 and 0.5 mm. The composite material structure according to claim 1, wherein the material of the core layer comprises a compound of acrylonitrile and methacrylic acid, polymethacrylimide, polyvinyl chloride, polystyrene, polyurethane, acrylonitrile-benzene Ethylene copolymer, polyetherimide, polypropylene, or combinations thereof. The composite material structure of claim 2, wherein the materials of the first adhesive layer and the second adhesive layer include polycaprolactone, polyether polyol, polyurethane or a combination thereof. The composite structure of claim 1, wherein the core layer has a thickness of 0.1 to 1.5 mm. The composite structure of claim 1, wherein the core layer has a density of 0.003 to 1 g/cm3. The composite material structure of claim 1, wherein the first carbon fiber layer is turned at the interface between the first block and the second block, and the first carbon fiber layer is in the first block. The height is higher than the height of the first carbon fiber layer in the second block. The composite material structure of claim 1, wherein a ratio of the first thickness to the second thickness is less than or equal to 15 and greater than 1. The composite material structure of claim 1, further comprising a plastic layer covering at least a portion of the first carbon fiber layer located in the second block. The composite material structure of claim 1, wherein the length of the first block is greater than the length of the second block.

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