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WO2011106909A1 - 金属基板与外饰层结合的复合板材及其制造方法 - Google Patents

金属基板与外饰层结合的复合板材及其制造方法 Download PDF

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Publication number
WO2011106909A1
WO2011106909A1 PCT/CN2010/000271 CN2010000271W WO2011106909A1 WO 2011106909 A1 WO2011106909 A1 WO 2011106909A1 CN 2010000271 W CN2010000271 W CN 2010000271W WO 2011106909 A1 WO2011106909 A1 WO 2011106909A1
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WO
WIPO (PCT)
Prior art keywords
layer
metal substrate
adhesive layer
tpr
thickness
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/CN2010/000271
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English (en)
French (fr)
Inventor
谢明仁
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pao Yi Tech Co Ltd
Original Assignee
Pao Yi Tech Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Pao Yi Tech Co Ltd filed Critical Pao Yi Tech Co Ltd
Priority to US13/582,719 priority Critical patent/US20120328826A1/en
Priority to PCT/CN2010/000271 priority patent/WO2011106909A1/zh
Publication of WO2011106909A1 publication Critical patent/WO2011106909A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/02—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch
    • B32B9/025—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising animal or vegetable substances, e.g. cork, bamboo, starch comprising leather
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/045—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/08—Dimensions, e.g. volume
    • B32B2309/10—Dimensions, e.g. volume linear, e.g. length, distance, width
    • B32B2309/105—Thickness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2319/00—Synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/20—Thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2451/00—Decorative or ornamental articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207—Heat-activated adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0004—Cutting, tearing or severing, e.g. bursting; Cutter details
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24298—Noncircular aperture [e.g., slit, diamond, rectangular, etc.]

Definitions

  • the invention relates to a composite board of a metal substrate and an outer layer and a manufacturing method thereof, in particular to a first TPR adhesive layer and a second TPR adhesive layer respectively attached to the surface of the metal substrate and the outer layer.
  • the TP A is composed of a styrene-butadiene block copolymer and a thermoplastic resin film synthesized by a hydrocarbon resin, and the outer layer and the metal substrate are passed through the first and second TPRs provided on the surface by a thermocompression bonding process.
  • the layers are laminated to each other to form a one-piece composite sheet which is supplied to form a shell. Background technique
  • the housing serves as the outer casing of the product; the housing has a different structure depending on the design requirements of the product, and if the material used for the base of the housing is roughly divided into a plastic housing and a metal housing Two main structural categories.
  • a plastic case having an outer decorative surface is generally formed by an in-mold decorating process (IMD), which is a carrier that will form a three-dimensional shape and print a pattern.
  • IMD in-mold decorating process
  • a plastic film hereinafter referred to as an IMD film (IMD film)
  • IMD film is embedded in a molding die, and a plastic injection molding process is used to project a hot melt resin on the back surface of the IMD film to form a substrate of the casing, hereinafter referred to as a resin.
  • the resin matrix and the IMD film are combined to form an integrated plastic shell, wherein the IMD film (IMD film) can be fixedly combined on the outer surface of the resin base to form a a permanent device for providing an outer decorative surface or a protective surface of the plastic housing or both; further, the IMD film may be temporarily fixed on the outer surface of the resin base. Forming a temporary device, the IMD film can be peeled off after completion, and the printed pattern on the IMD film is transferred or left on the outer surface of the resin substrate as the plastic shell An outer decorative surface of the body.
  • IMD film IMD film
  • No. 3,654,062 discloses a related art of a molded decorative plaque having a laminated facing sheet which is formed by injection molding a hot melt plastic into a mold having a mold configuration. The surface sheet is formed on the back surface.
  • US 6,117,384 discloses a related art method for forming a permanently bonded solid object by using a film having a colorful color and then projecting a hot melt resin on the back side of the film.
  • US 4,391,954 discloses the inclusion of aromatic carbonate polymers and rings A related art of a thermoplastic molding compound of a polyester obtained from cyclohexanedimethanol.
  • US 4,125,572 discloses thermoplastic molding comprising an aromatic carbonate polymer and a polyester obtained from a cycloaliphatic diol or a cycloaliphatic diol.
  • Related technology of composite plastic molding.
  • No. 6,465,102 discloses an article comprising a decorative surface region and an integrally formed polymeric base and a molding method thereof, and the polymeric matrix comprises a transparent cycloaliphatic polyester resin
  • An example of a cycloaliphatic polyester resin is disclosed in the form of a decorative surface area and an integral formed polymeric base comprising a transparent cycloaliphatic polyester resin. Free from an aromatic moiety and the method of molding thereof ).
  • US 6,117,384 discloses a related art of an in-mold decorating process (IMD). No.
  • 6,136,441 discloses related art of multilayer plastic articles.
  • these prior art techniques mostly include a plastic film (i.e., IMD film) and a resin contained in a plastic case.
  • the resin base is further limited, for example, by defining a plastic film (IMD film) or a resin base as a special chemical family plastic material, thereby forming a stable bond and not easily peeling off.
  • IMD film plastic film
  • resin base is further limited, for example, by defining a plastic film (IMD film) or a resin base as a special chemical family plastic material, thereby forming a stable bond and not easily peeling off.
  • One-piece composite plastic sheet and can be distinguished from other patents (prior art).
  • the plastic shield film i.e., IMD film
  • the resin base of the plastic shell article composed of the composite material are specifically defined, not only the materials used are limited but also plasticized.
  • the application of plasma membranes (ie, IMD membranes) and/or resin bases is relatively limited, which is not conducive to the application of the molded plastic shells, for example, for the sake of diversification, but not limited to the fabric surface.
  • a material such as a leather surface or a resin fiber surface is used as a plastic film, it is often impossible to use the same technology or equipment and achieve high productivity, mass production, and good quality control, and it is relatively impossible to lift the plastic case. The efficiency of use and the range of applications are therefore considered to be disadvantages of these plastic shell articles.
  • the more common metal casing comprises: a shell shape formed by machining a thin metal plate such as an aluminum alloy sheet, or further surface-treated on the outer surface of the metal shell shape to give a gloss or Patterning, or further providing a resin layer such as a resin film on the outer surface of the metal casing shape to protect the outer surface of the metal from being scratched, bumped, etc. during use, or further in the shape of the metal casing
  • the outer surface of the outer surface is further provided with a patterned resin layer for protecting the outer surface of the metal and enhancing the aesthetic or tactile sensation of the product, or using plastic injection molding technology or injection bonding as the assembly of internal components of the product is required.
  • the fixing method (only refers to the molding method by injection molding) directly sets or bonds and fixes various assembling plastic members such as flange shapes or rib shapes on the inner surface of the metal casing shape, It is used to simplify the structure and overall thickness of these plastic parts for assembly and to improve the structural strength.
  • Chinese Patent Application No. ZL02805359.1 discloses a composite of an aluminum alloy and a resin and a related art thereof, characterized in that it comprises: In the aluminum alloy shape of the step, the contacting step is such that the aluminum alloy shaped article is contacted with an aqueous solution of one or more compounds selected from the group consisting of ammonia, hydrazine (hydrazine), methylamine, and ethylenediamine.
  • the copolymer having an alkyl ester as a main component and one or more thermoplastic compositions containing the above polyalkylene terephthalate component.
  • Chinese Patent Application No. ZL200380102886.0 discloses a composite of an aluminum alloy and a resin and a related art thereof, characterized in that it is selected An aluminum alloy shaped article impregnated in an aqueous solution of one or more aqueous solutions of ammonia, hydrazine (hydrazine) and a water-soluble amine compound, and integrally adhered to the surface of the aluminum alloy shaped article, and containing a polyphenylene ether component Composition of a thermoplastic composition.
  • Chinese Patent Application No. ZL200380104500.X discloses a composite of an aluminum alloy and a resin and a related art thereof, characterized by surface roughness
  • An aluminum alloy shape having a fine concave portion or a convex portion of 5 ⁇ to 50 ⁇ m and having a surface of ⁇ or less, and a pair of immersed in the concave portion or the convex portion, and having a longitudinal and transverse average linear expansion coefficient of 2 to 4 ⁇ 10 ⁇ 5 XT 1
  • a thermoplastic composition comprising a butylene phthalate resin or a polyphenylene hydride as a main component.
  • the resin and secondary components are impact-resistant improved materials.
  • the above-mentioned Chinese invention patents ZL02805359.1, ZL200380102886.0, ZL200380104500.X ZL200680046075.7 are all related technologies for revealing a composite of metal and resin and a manufacturing method thereof, and each of its characteristics is that the metal (such as aluminum)
  • the alloy is an impregnation process in which a specially selected aqueous solution (for example, an aqueous solution of one or more water-soluble amine compounds) is impregnated, and then a thermoplastic resin having a specific selection component is integrally attached to the aluminum alloy shape by injection molding.
  • the steps of the metal (aluminum alloy) shape of the composite and the components of the resin shape are specifically limited, and relatively complicated, so that the method and application of the composite are affected.
  • the limitation is not conducive to the use efficiency and application range of the metal casing, and in particular, the use of a specially selected aqueous solution is less in line with the current environmental protection requirements, and thus can be regarded as a disadvantage of the above metal casing articles.
  • the domestic invention patent application No. 85100575 (Announcement No. 404888) "high-precision resin-coated metal sheet having excellent processing adhesion” discloses a related technique of a resin-coated metal sheet, which is based on a metal plate, at least On the surface of the substrate, a 5 - ⁇ thick denatured acryl resin layer, a pattern and/or a coating layer, a polypropylene copolymer 100 - 20 parts by weight, and a polypropylene 100 - 0 parts by weight are laminated in this order from the substrate side.
  • a full-printing layer, a subsequent layer, a polyester resin film of 5 to 100 ⁇ m thick see claim 1
  • a coating layer, a pattern and/or a comprehensive printing layer, polypropylene copolymerization sequentially laminated from the substrate side 100 to 20 parts by weight and 100 to 0 parts by weight of polypropylene, 5 to ⁇ thick thick acryl resin layer, adhesive layer, 5 ⁇ ⁇ thick polyester resin film (see claim 2);
  • the substrate side is sequentially laminated with a coating layer, a polypropylene copolymer of 100 to 20 parts by weight, and a polypropylene of 100 to 0 parts by weight, a 5 to ⁇ thick denatured acryl resin layer, a binder layer, and 5 ⁇ 100 ⁇ thick transparent polyester resin film (see claim 3); or a coating layer, 5 ⁇ 100 ⁇ thick thickened olefin layer, a subsequent layer, 5 ⁇ ⁇ thick transparent poly layer sequentially laminated from the substrate side An ester resin film (Claim 4).
  • the composition of the resin coating layer sequentially laminated from the substrate side has been specifically defined, and the main purpose is that the resin-coated metal sheet has high vividness, and the shape of the metal sheet is restricted. , is not conducive to the application of the fabricated metal shell.
  • a related art of coating a resin metal sheet which includes:
  • the sheet metal piece has an arithmetic mean deviation (Ra) value of roughness between 0 ⁇ m and 10 ⁇ m; a transparent soft resin layer including an uncured mixed type resin layer, and a polyester resin coating a coating, or a polyolefin resin; an adhesive layer comprising a pigment; a transparent resin film having a gloss treated on both sides, wherein at least one metal sheet surface is covered by a colored layer, a soft resin layer, a subsequent layer and a transparent layer, each layer being a metal
  • the metal sheets are sequentially laminated.
  • composition of the resin coating layer has been specifically defined, and the main purpose is that the resin-coated metal sheet has a high color sexuality, the shape of the metal plate is limited, which is not conducive to the application of the fabricated metal casing.
  • 404888 is modified to disclose a related art of an aluminum alloy substrate provided with a film layer, the method comprising at least: a "coating adhesive” step, which is at least one of a metal substrate made of an aluminum alloy The side surface is coated with a layer of an adhesive, and the adhesive has a metal powder; a "bake heating” step of heating the metal substrate of the adhesive to soften the adhesive; a “rolling” step, via The heated roller roll-rolls a film layer on the adhesive layer, wherein the film layer is formed by laminating at least one polyvinyl chloride layer, an adhesive layer and a polyester layer in sequence, and the subsequent layer has Metal powder; a "cooling forming” step of adhering the film layer to the metal substrate.
  • the composition of the film layer laminated on the side surface of the aluminum alloy metal substrate is formed by laminating at least one polyvinyl chloride layer, one adhesive layer and one polyester layer in sequence, so that the film
  • the layer has been specifically defined to limit the appearance of the metal substrate, which is disadvantageous for the application of the fabricated metal casing (ie, the electronic device housing metal plate).
  • the domestic patent application No. 093210282 (Certificate No. M261368) "Electronic device housing metal plate structure" is a novel patented invention of the structure of the aforementioned invention patent application No. 093119015 (Certificate No. 1280190).
  • the structure of the invention also has the disadvantage that the film layer of the invention patent application No. 093119015 has been specifically defined.
  • Complement metal plate structure discloses a composite resin layer comprising a metal substrate, coated on the metal substrate and heated and softened, and rolled and laminated on a roll The metal panel on the composite resin layer causes the metal panel to be intimately bonded to the metal substrate.
  • the second outer side of the structure of the present invention is a metal plate and a metal substrate, so that there are disadvantages in that the two outer sides have been specifically defined.
  • the domestic new patent application No. 096215339 (Certificate No. M328384) "Environmental-type skinned metal structure” discloses a related art of a veneered metal structure, which at least includes: a metal substrate; coated on at least one side of the aforementioned metal substrate a surface layer and a layer of an adhesive layer which is appropriately softened; and a film layer which is formed by laminating a polyurethane underlayer and a polyurethane surface layer in a stepwise manner, is rolled on a roller to be laminated on the adhesive layer, and then cooled. The film layer is bonded to the metal substrate in close contact.
  • composition of the film layer in the structure of the invention is formed by sequentially laminating a polyurethane underlayer and a polyurethane surface layer, so that the film layer has been specifically defined so that the shape or feel of the metal substrate is relatively affected.
  • the limitation is not conducive to the application of the fabricated metal casing.
  • An object of the present invention is to provide a composite board in which a metal substrate and an outer layer are combined, and the metal substrate to the outer layer sequentially comprises: a metal substrate, a first TPR adhesive layer, a second TPR adhesive layer, and a Exterior layer, where:
  • the metal substrate is a thin metal plate having a suitable thickness, and the surface thereof has a plurality of nearly uniformly covered fine concave holes which are naturally generated on the surface of the metal substrate during the molding process;
  • the first TPR adhesive layer is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of 400-500 ⁇ , which is heat-pressed by a heating method of a roller or a flat plate. On a side surface of the metal substrate, and a part of the thickness thereof penetrates into the plurality of fine recessed holes on the surface of the metal substrate in the thermocompression bonding;
  • the second TPR adhesive layer is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of 400-500 ⁇ m, which is attached to one surface of the exterior layer;
  • the exterior layer is a decorative layer having a plurality of nearly uniformly covered pores on the surface thereof, the pores being naturally generated on the surface during the molding process of the exterior layer;
  • the metal substrate and the outer layer are thermocompression bonded to each other by a thermocompression bonding process to form a composite sheet;
  • the first TPR adhesive layer and the second TPR adhesive layer are simultaneously thermally fusion bonded to each other, and the second TPR adhesive layer is a portion of the thickness simultaneously penetrates into the plurality of pores in the surface of the outer layer, so that the outer layer is adhered to the first surface of the metal substrate by the second TPR adhesive layer and the first TPR adhesive layer, and Achieve the degree of adhesion that allows deep processing without peeling.
  • the metal substrate is an aluminum alloy plate.
  • the outer layer is a cloth layer composed of natural fibers such as cotton, hemp or animal fiber hair, silk, or rayon fibers such as nylon, polyester fiber, or acrylic fiber.
  • the outer layer is a leather layer composed of natural leather such as sheepskin or cowhide, or composed of PU, PVC or PU and PVC synthetic leather.
  • the exterior layer is a bamboo layer composed of a bamboo piece that has been cut into a sheet shape.
  • the exterior layer is a layer of wood composed of wood chips that are cut into sheets.
  • the first TPR adhesive layer has a thickness of 10% in the range of 400-500 ⁇ (10' 6 m ), that is, a thickness of about 40-50 ⁇ The degree penetrates into the plurality of fine recessed holes on the surface of the metal substrate in the thermocompression bonding.
  • Another object of the present invention is to provide a method for producing the composite sheet, comprising the steps of: providing a metal substrate having a suitable thickness, and the surface of the metal substrate has a substantially uniform coverage on the surface thereof due to its molding method; a plurality of fine recessed holes on the surface;
  • a layer of thickness is hot pressed on one side surface of the metal substrate by heating or pressing of a roller or a flat plate
  • the TPR adhesive layer is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and the first TPR adhesive layer is about 10% (about a portion of the thickness of 40-50 ⁇ ) penetrates into a plurality of existing fine recessed holes on the surface of the metal substrate during hot pressing;
  • an outer decorative layer having a suitable thickness and the surface of the outer decorative layer naturally has a plurality of fine holes substantially covering the surface thereof due to a molding process thereof;
  • a second TPR adhesive layer having a thickness of 400-500 ⁇ m (l(T 6 m )) is adhered to a surface of the outer decorative layer by heating the roller, and the TPR adhesive layer is composed of a styrene-butadiene block copolymer and a thermoplastic rubber film composed of a hydrocarbon petroleum resin;
  • the metal substrate and the outer layer are subjected to a thermocompression bonding step such that the metal substrate and the outer layer are thermally bonded to each other through the first and second TPR adhesive layers provided on the respective surfaces, and The second TPR adhesive layer is infiltrated into the plurality of pores existing on the surface of the outer decorative layer in the hot press bonding process and simultaneously bonded to the first TPR adhesive layer on the metal substrate;
  • an integrated composite sheet having a metal substrate and an outer layer is formed.
  • the metal substrate is an aluminum alloy plate.
  • the material of the outer layer comprises one of the following groups: the cloth layer is composed of natural or man-made fibers, the leather layer is composed of natural or PU/PVC synthetic skin, and the bamboo layer is composed of bamboo pieces which are cut into thin pieces, Or the wood layer consists of wood chips that are cut into thin slices.
  • the hot press bonding process further includes a baking heating process for baking and heating the first TPR adhesive layer provided on the surface of the metal substrate to heat the first TPR adhesive layer to about 130 ° C. Make it softer to facilitate the cooperation.
  • thermocompression bonding step further includes a baking heating process for performing a baking heating operation on the second TPR adhesive layer provided on the surface of the outer decorative layer to heat the second TPR adhesive layer to about 130°. C, soften it properly to facilitate the covering operation.
  • thermocompression bonding process further utilizes a heated roller maintained at a temperature of about 140 ° C for rolling the outer layer through the second TPR adhesive layer on the surface thereof to roll the first TPR of the metal substrate. Adhesive layer, so that the outer layer is closely bonded to the metal substrate.
  • the composite board of the present invention and the method for preparing the same since the outer layer can optionally use a cloth layer, a leather layer or a synthetic skin layer, a natural or synthetic resin fiber surface layer, or the like, the composite sheet or the formed shell
  • the shape can have various appearance patterns and/or touches, increase the diversification of the appearance of the product and the selectivity of the consumer, which is beneficial to the value of the product and the market competitiveness, and can avoid the prior art.
  • Different materials of the decorative layer require a different set of preparation methods and equipment to complete the trouble of the composite sheet, and achieve the practical effect of high production efficiency, easy mass production, deep drawing processing and good quality control.
  • FIG. 1 is a schematic flow chart of a method for preparing a composite board of the present invention
  • Figure 2 is a schematic cross-sectional view showing a composite sheet structure of the present invention
  • Figure 3 is a front perspective view showing a shape of a casing formed by the extrusion press forming process of the composite sheet of the present invention
  • Figure 4 is a rear perspective view of Figure 3.
  • the above and other technical features and advantages of the present invention are described in more detail below with reference to the accompanying drawings.
  • the method for preparing the composite sheet 1 of the present invention mainly comprises the following steps:
  • a metal substrate 10 having a suitable thickness is provided; the metal substrate 10 includes, but is not limited to, an aluminum alloy thin plate, and the surface of the metal substrate 10 naturally has a plurality of near-uniformly scattered distributions according to a molding process of a general metal substrate. Fine KJ hole; ⁇
  • an outer cover layer 30 having a suitable thickness is provided;
  • the outer cover layer 30 includes, but is not limited to, one of the following groups: a cloth layer composed of natural or rayon fibers, such as a natural or PU/PVC synthetic skin. a leather layer, a bamboo layer composed of a thinned bamboo piece, or a wood layer formed of a chipped wood piece, and the like, and a general molding process of the outer layer 30 on the surface thereof Naturally, there are several fine holes that can be regarded as nearly uniform dispersion;
  • the second TPR adhesive layer 40 having a thickness of about 400-500 ⁇ m is applied by heating with a roller but without pressure or with a little pressure, and the second TPR is adhered.
  • the layer 40 does not penetrate into the existing plurality of pores on the surface of the outer layer;
  • the metal substrate 10 and the exterior layer 30 are subjected to a thermocompression bonding step such that the metal substrate 10 and the exterior layer 30 are provided to each other through the first and second TPR adhesive layers 20 and 40 provided on the respective surfaces.
  • the thermocompression bonding is performed, and the second TPR adhesive layer 40 can be infiltrated into the plurality of pores existing on the surface of the exterior layer 30 and simultaneously with the first TPR on the metal substrate 10 in the thermocompression bonding process.
  • the adhesive layer 20 is firmly and tightly combined;
  • an integrated composite sheet 1 having a metal substrate 10 and an outer layer 30 is formed as shown in FIG.
  • the second TPR adhesive layer 40 can penetrate into the existing plurality of pores on the surface of the exterior layer 30 and simultaneously with the metal substrate 10 in the thermocompression bonding process.
  • the first TPR adhesive layer 20 is firmly heat-sealed and integrated, so that the composite sheet 1 can maintain a relatively good adhesion between the metal substrate 10 and the outer layer 30, and after the physical test, It is proved to be able to withstand various deep-forming forming operations such as deep drawing, drawing, cutting, etc.; therefore, the composite sheet 1 of the present invention can be subjected to deep processing forming work as required for design, and is used for both strength advantages and decoration.
  • the housing shape 2 of the aesthetic advantage, as shown in Figs. 3 and 4 avoids the disadvantages of the prior art adhesive effect and poor molding quality, and the material used for the outer layer is often relatively limited.
  • the process of the present invention is more in line with current environmental requirements than the prior art.
  • the method of the present invention utilizes a plurality of fine recesses formed on the surface of the metal substrate 10 which are naturally formed and nearly uniformly dispersed in the molding process, so that a part of the thickness of the first TPR adhesive layer 20 can be in the hot pressing step. Directly infiltrating into these fine recesses, so the method of the present invention does not utilize any special aqueous solution or any related process of immersing the metal substrate in a special aqueous solution to form or cover a plurality of depths on the surface of the metal substrate. Or a recess of the inner diameter to shape and adhere a thermoplastic resin having a special composition to the surface of the metal substrate, such as Chinese patents ZL02805359.1, ZL200380102886.0,
  • a purification process step may be taken for the surface state of the metal substrate 10, and the purification process step includes, but is not limited to, degreasing.
  • the main purpose is to maintain the working surface of the metal substrate 10 in a certain degree of clean state, so as to avoid adversely affecting the hot pressing operation procedure of the subsequent first TPR adhesive layer 20, thereby making the first TPR A good close adhesion effect is achieved between the adhesive layer 20 and the surface of the metal substrate 10.
  • thermocompression bonding step used to bond the exterior layer 30 and the metal substrate 10 in close contact
  • the following steps may be included without limitation: For example, before the hot press bonding step, a baking is performed. a baking heating process for baking and heating the first TPR adhesive layer 20 provided on the surface of the metal substrate 10, so that the first TPR adhesive layer 20 can be heated to about 130 ° C and softened appropriately. It is advantageous to perform a thermocompression bonding process with the second TPR adhesion layer 40 provided on the surface of the exterior layer 30; another baking heating process may be further performed for setting the surface of the exterior layer 30.
  • the second TPR adhesive layer 40 is subjected to a baking heating operation so that the second TPR adhesive layer 40 can be heated to about 130 ° C to be appropriately softened to facilitate the first TPR adhesive layer 20 provided on the surface of the metal substrate 10.
  • a hot press bonding process is performed.
  • the hot press bonding process can be performed by using a heated roller, and the temperature of the roller can be maintained at about 140 ° C for rolling the outer layer 30 through the second TPR adhesive layer 40.
  • the structure of the integrated composite sheet 1 of the present invention comprises: a metal substrate 10, a first TPR adhesive layer 20, a second TPR adhesive layer 40, and an outer decorative layer 30.
  • the metal substrate 10 is a metal element that can be used to form the housing shape 2 of an electronic device.
  • the housing shape 2 is shown in FIGS. 3 and 4 and is not limited to a computer product or communication.
  • a casing of a 3C product such as a product or a consumer product, generally using a metal plate such as an aluminum alloy plate of good light strength;
  • the surface 11 of the metal substrate 10 has substantially a plurality of fine recessed holes 12 (for It is obvious that the recessed holes 12 in the figure are enlarged and can be regarded as being nearly uniformly spread or covered on the surface 11, and the fine recessed holes 12 are formed by a press forming process in the molding process of the general metal substrate 10. Naturally occurring on the surface, it is not formed by any special process or any relevant process of immersing the metal substrate 10 in a special aqueous solution.
  • the surface of one side is integrated with the metal substrate 10, and a part of the thickness of the first TPR adhesive layer 20, such as about 10% of the original thickness, is about 40-50 ⁇ , which can penetrate into the metal in the hot press bonding industry.
  • the adhesion strength between the first TPR adhesive layer 20 and the metal substrate 10 is increased to prevent peeling or breakage during deep drawing.
  • the outer side of the first TPR adhesive layer 20 is indicated by the interface 21.
  • the second TPR adhesive layer 40 is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and may be identical to the material of the first TPR adhesive layer 40, or have the same material composition but different mixing ratios.
  • the TPU.TPE film in addition, the second TPR adhesive layer 40 has a thickness of about 400-500 ⁇ m, which is attached to the surface 31 of the exterior layer 30 by heating of the roller but without pressure or only a little pressure. Above, but in the attaching operation, the second TPR adhesive layer 40 does not penetrate into the existing plurality of pores 32 on the surface 31 of the exterior layer 30 due to the heating of the roller but no pressure or only a slight pressure.
  • the second TPR adhesive layer 40 does not penetrate into the plurality of fine holes 32 on the surface 31 of the exterior layer 30 before the metal substrate 10 and the exterior layer 30 are subjected to the thermocompression bonding process.
  • the outer side of the second TPR adhesive layer 40 is indicated by the interface 41.
  • the composite sheet 1 shown in FIG. 3 is a molded product after the thermocompression bonding process, in which case the metal substrate 10 and the exterior layer 30 have been mutually pressed by the first and second TPR adhesive layers 20, 40.
  • the bonding that is, the first and second TPR adhesive layers 20, 40 are mutually thermally fused, so that the original interface 21/ of the first and second TPR adhesive layers 20, 40 cannot be retained or marked in FIG. 41. Therefore, in Fig. 3, two appropriately spaced dotted lines 50 are used to indicate the splice state between the original interfaces 21/41.
  • the exterior layer 30 includes, but is not limited to, one of the following groups: a cloth layer composed of natural fibers such as cotton, hemp or the like of animal fibers, wool, silk, etc., or rayon such as nylon, poly a polyester fiber or an acrylic fiber; a leather layer composed of natural skin or PU PVC synthetic skin; a bamboo layer composed of bamboo pieces which are cut into thin pieces; or a wood layer which is cut into thin pieces
  • the outer layer 30 can be processed separately as required by the orderer to have various appearance patterns or touches;
  • the molding process of the veneer 30 naturally has a plurality of pores 32 that can be considered to be nearly evenly distributed, such as meshes of natural or man-made fibers or capillary pores of natural skin.
  • the second TPR adhesion layer 40 can simultaneously penetrate into the plurality of pores 32 of the surface 31 of the exterior layer 30 to
  • the outer decorative layer 30 can be adhered to one side surface of the metal substrate 10 through the second TPR adhesive layer 40 and the first TPR adhesive layer 20, and a degree of close adhesion which allows deep processing without peeling is achieved.
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate 10 by heating or pressing of a roller or a flat plate, the overall thickness becomes about 360-450 ⁇ m;
  • the outer layer 30 is a cloth layer having a thickness of 0.3 mm formed of wool, silk, or the like of natural fibers such as plant fibers, wool or silk, and the second TPR adhesive layer 40 provided on the surface thereof is
  • the benzene block copolymer is composed of a thermoplastic rubber film synthesized by a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the thermocompression bonding process, the formed composite sheet 1 has a thickness of 1.1 mm;
  • the peel strength of the present embodiment was 5 kg per square centimeter, and the environmental test adhesion was from -40 ° C to 85 ° C and from 85 ° C to -40 ° C, and the temperature was raised or lowered by 1 ° C per minute.
  • the shape of the casing formed of the composite sheet is shown in Figs. 3 and 4 after 4 cycles, wherein the exterior layer 30 and the aluminum alloy sheet 10 are not peeled off.
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate 10 by heating or pressing of a roller or a plate, the thickness becomes about 360-450 ⁇ m;
  • the outer layer 30 is a cloth layer composed of rayon fibers such as nylon, polyester fiber, acrylic fiber and having a thickness of 0.3 mm, and the second TPR adhesive layer 40 provided on the surface thereof is copolymerized by styrene-butadiene block.
  • the composition is composed of a thermoplastic rubber film synthesized by a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the thermocompression bonding process, the formed composite sheet 1 has a thickness of 1.1 mm;
  • the peel strength of the present embodiment was 5 kg per square centimeter
  • the shape of the casing formed by the environmental test adhesion material was as shown in Figs. 3 and 4, wherein the outer layer 30 and the aluminum alloy plate 10 were not peeled off. .
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate by heating or pressing of a roller or a flat plate After 10, the thickness becomes about 360-450 ⁇ ;
  • the outer layer 30 is a leather layer composed of natural leather sheepskin and having a thickness of 0.4 mm, and the second TPR adhesive layer 40 provided on the surface thereof is a thermoplastic synthesized from a styrene-butadiene block copolymer and a hydrocarbon resin. a rubber film, having a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the thermocompression bonding process, the formed composite sheet 1 has a thickness of 1.2 mm;
  • the peel strength of the present embodiment was 5 kg per square centimeter, and the environmental test adhesion was from -40 ° C to 85 ° C and from 85 ° C to -40 ° C, and the temperature was raised or lowered by 1 ° C per minute.
  • the shape of the casing formed of the composite sheet is shown in Figs. 3 and 4 after 4 cycles, wherein the exterior layer 30 and the aluminum alloy sheet 10 are not peeled off.
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate 10 by heating or pressing of a roller or a flat plate, the thickness becomes about 360-450 ⁇ m;
  • the outer layer 30 is a leather layer composed of PU/PVC synthetic skin and having a thickness of 0.5 mm, and the second TPR adhesive layer 40 provided on the surface thereof is a heat synthesized by the styrene-butadiene block copolymer and the hydrocarbon resin.
  • the plastic rubber film is formed to have a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the thermocompression bonding process, the formed composite sheet 1 has a thickness of 1.3 mm;
  • the peel strength of the present embodiment was 5 kg per square centimeter
  • the shape of the casing formed by the environmental test adhesion material was as shown in Figs. 3 and 4, wherein the outer layer 30 and the aluminum alloy plate 10 were not peeled off. .
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate 10 by heating or pressing of a roller or a flat plate, the thickness becomes about 360-450 ⁇ m;
  • the outer layer 30 is a bamboo layer composed of a thinned bamboo piece and having a thickness of 0.4 mm, and the second TPR adhesive layer 40 provided on the surface thereof is synthesized from a styrene-butadiene block copolymer and a hydrocarbon resin.
  • the thermoplastic rubber film is formed to have a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the hot pressing bonding process, the formed composite sheet 1 has a thickness of 1.2 mm; As a result, it was found that the peel strength of the present embodiment was 5 kg per square centimeter, and the environmental test adhesion was from -40 ° C to 85 ° C and from 85 ° C to -40 ° C, and the temperature was raised or lowered by 1 ° C per minute.
  • the shape of the casing formed of the composite sheet is shown in Figs. 3 and 4 after 4 cycles, wherein the exterior layer 30 and the aluminum alloy sheet 10 are not peeled off.
  • the composite sheet 1 of the present embodiment comprises:
  • the metal substrate 10 is an aluminum alloy plate having a thickness of 0.8 mm, and the first TPR adhesive layer 20 on the surface thereof is composed of a thermoplastic rubber film synthesized from a styrene-butadiene block copolymer and a hydrocarbon petroleum resin, and has a thickness of about 400-500 ⁇ ; and when the first TPR adhesive layer 20 is hot pressed on the aluminum alloy plate 10 by heating or pressing of a roller or a plate, the thickness becomes about 360-450 ⁇ m;
  • the outer layer 30 is a bamboo layer composed of wood flakes cut into a sheet shape and having a thickness of 0.4 mm, and the second TPR adhesive layer 40 provided on the surface thereof is synthesized from a styrene-butadiene block copolymer and a hydrocarbon resin.
  • the thermoplastic rubber film is formed to have a thickness of about 400-500 ⁇ m;
  • the formed composite sheet 1 After the thermocompression bonding process, the formed composite sheet 1 has a thickness of 1.2 mm;
  • the peel strength of the present embodiment was 5 kg per square centimeter, and the environmental test adhesion was from -40 ° C to 85 ° C and from 85 ° C to -40 ° C, and the temperature was raised or lowered by 1 ° C per minute.
  • the shape of the casing formed of the composite sheet is shown in Figs. 3 and 4 after 4 cycles, wherein the exterior layer 30 and the aluminum alloy sheet 10 are not peeled off.

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Description

金属基板与外饰层结合的复合板材及其制造方法 技术领域
本发明涉及一种金属基板与外饰层的复合板材及其制造方法， 尤指一种在金属 基板与外饰层的表面先分别贴合一第一 TPR黏着层和一第二 TPR黏着层， 该 TP A 由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜， 再通过一次热压贴合 工序使该外饰层及金属基板经由表面上所设的第一与第二 TPR占着层而相互热压贴 合以形成一体式复合板材， 供应用于制成壳体状物。 背景技术
市面上各种电子产品， 包含但不限制于常见的计算机（computer )产品如笔记 型计算机 ( Notebook computer, 简称 NB )、 通讯 ( communication )产品如手机或 消费性（consumer )产品等 3C产品， 常用壳体作为产品的外壳； 该壳体随产品的设 计要求而具有不同的结构， 而若就壳体的基体（base )所使用的材质而言， 可大致 分为塑质壳体及金属壳体两个主要结构类别。
具有外在装饰面的塑质壳体一般是利用嵌入模具式装饰方法（in-mold . decorating process, 简称 IMD )制成， 其是将形成三度空间成型形状且印刷有图案的 载体（substrate )如塑质膜， 以下简称 IMD膜（ IMD film )， 嵌置于成型模具内， 再 利用塑料射出成型工艺使热熔树脂射出成型在该 IMD膜的背面以形成该壳体的基 体， 以下简称树脂基体（resin base ), 使该树脂基体与 IMD膜结合构成一体式塑质壳 体， 其中， 该 IMD膜（IMD film )可以固定结合方式设在树脂基体 ( resin base ) 的 外表面上而形成一永久性装置物， 供作为该塑质壳体的一外装饰面或一保护面或二 者皆是； 此外， 该 IMD膜亦可以暂时固定方式设在树脂基体 ( resin base ) 的外表面 上而形成一暂时性装置物, 完成后可将该 IMD膜撕离， 并使该 IMD膜上的印刷图案 转印或留存在树脂基体的外表面上供作为该塑质壳体的一外装饰面。
针对上述塑质壳体的结构设计及其制造方法， 目前存在很多现有技术， 包含：
US3,654，062揭示了具有压合式表面片 （ a laminated facing sheet )的模制饰板 ( a molded decorative plaque )的相关技术， 其是将热熔塑料射出成型在一已具有模具构 造的压合表面片的背面上而形成。 US6，117,384揭示了利用具有多彩颜色的薄膜， 再 将热熔树脂射出成型在该薄膜的背面而构成永久结合的立体对象的方法相关技术。 US4,391,954揭示了包含芳香族碳酸盐聚合物 （ aromatic carbonate polymer )与由环 己烷族（ cyclohexanedimethanol )取得的多元酯（polyester ) 的热塑型模制复合体 ( thermoplastic molding composition ) 的相关技术。 US4, 125,572揭示了包含芳香族 碳酸盐聚合物 ( aromatic carbonate polymer )与由月旨肪族 ( aliphatic )或环月旨肪族 ( cycloaliphatic diol )取得的多元酯（ polyester )的热塑型模制复合体 ( thermoplastic molding composition ) 的相关技术。 US6,465，102揭示了包含一装饰用表面区域及一 个一体式形成的聚合基体 ( polymeric base )的物品及其模制方法， 且该聚合基体包 含透明的环脂肪族多元酯树脂（ cycloaliphatic polyester resin )， 其中该环脂肪族多元 酯树脂是不受芳香族部分 ( aromatic moiety )干扰的相关技术（ An article comprising a decorative surface area and an integral formed polymeric base comprising transparent cycloaliphatic polyester resin, wherein the cycloaliphatic polyester resin is free from an aromatic moiety and the method of molding thereof )。 US6， 117,384揭示了改良的嵌入模 具式装饰用工艺 （in-mold decorating process, IMD ) 的相关技术。 US6,136，441揭示 了多层式塑质物品（ multilayer plastic articles )的相关技术。 参考上述各种有关塑质 壳体的结构设计或制造方法等现有技术的专利说明书内容， 可知这些现有技术大都 是将一塑质壳体所包含的塑质膜（即 IMD膜）及树脂基体 ( resin base )分别作出进 一步的限定（limitation ), 如将塑质膜（IMD膜）或树脂基体 ( resin base )限定为某 一特殊化学族塑质材料， 从而制成一稳固结合不易剥离的一体式复合塑质板材， 且 又可与其它专利 （现有技术）之间有区别性。
然而， 当由复合材构成的塑质壳体物品的塑盾膜（即 IMD膜）和 /或树脂基体 ( resin base )被分别特殊化限定时， 不但使所使用的材料受到限制，也使塑质膜（即 IMD膜）和 /或树脂基体（resin base )的应用相对受到限制， 不利于所制成的塑质壳 体的应用， 例如为多样化需要而欲选用包含但不限制于布面、 皮革面、 树脂纤维面 等材料来作为塑质膜时， 则往往无法利用相同的技术或设备并达成生产效率高、 可 量产化且质量控管佳的功效， 相对无法提升该塑质外壳的使用效率及应用范围， 因 此可视为上述这些塑质壳体物品的缺点。
此外， 较常见的金属壳体包含： 以金属薄板如铝合金薄板通过机械加工制成的 壳体形状物， 或进一步在该金属壳体形状物的外表面上另作表面加工处理以呈现光 泽或图案， 或进一步在该金属壳体形状物的外表面上另再设置一树脂层如树脂薄膜 用以保护金属外表面以避免使用中受到刮、 碰等损伤， 或进一步在该金属壳体形状 物的外表面上另设置一层具有图案的树脂层， 用以保护金属外表面并增进产品的外 观美感或触感， 或随产品内部组件的组装需要而利用塑料射出成型技术或注塑粘合 固着方式（只指通过注塑成型的成型方式）直接在该金属壳体形状物的内表面上适 位处设置或粘合固着各种组装用塑^构件如凸缘形状物或肋板形状物， 用以简化这 些组装用塑质构件的结构及整体厚度， 并增进结构强度。
针对上述金属壳体的结构设计及其制造方法， 目前已存在很多现有技术， 包含 美国发明专利 US5,695,699 , US5,472,782及美国发明专利公开发明 US2009/0117401、 US2008/0127479、 US2007/0218721等， 现以下列专利分别说明：
中国发明专利申请号 ZL02805359.1 (国际申请 PCT I JP2002/007267, 国际公布 WO2003/064150 )揭示了一种铝合金与树脂的复合体及其制造方法的相关技术， 其 特征在于， 包括： 经过接触工序的铝合金形状物， 所述的接触工序是使铝合金形状 物与溶解选自氨、 肼 （联胺）、 甲基胺及乙二胺中的一种以上的化合物的水溶液接 触， 使上述水溶液吸附、 残留在其表面的工序， 和通过注塑成型一体地附着在前述 铝合金形状物的树脂， 所述树脂选自聚对苯二甲酸亚烷基酯、 以前述聚对苯二曱酸 亚烷基酯为主体的共聚物、 和含有前述聚对苯二甲酸亚烷基酯成分的热塑性组合物 中的一种以上。
中国发明专利申请号 ZL200380102886.0 (国际申请 PCT/JP2003/014213 , 国际公 布 WO2004/041532 )揭示了一种铝合金与树脂的复合体及其制造方法的相关技术， 其特征在于， 由经过在选自氨、 肼（联胺）和水溶性胺化合物一种以上的水溶液中 浸渍的浸渍工序的铝合金形状物以及一体地附着在所述铝合金形状物的表面上、 含 有聚苯琉醚成分的热塑性组合物构成。
中国发明专利申请号 ZL200380104500.X (国际申请 PCT/JP2003/014214, 国际 公布 WO2004/041533 )揭示了一种铝合金与树脂的复合体及其制造方法的相关技术， 其特征在于， 由表面粗糙度为 5μπι ~ 50μιη且其表面具有 Ιμιη以下的微细凹部或凸部 的铝合金形状物， 与浸入所述凹部或凸部而固定、 纵横平均线膨胀系数为 2 ~ 4χ10·5 XT1的以聚对苯二曱酸丁二醇酯树脂或聚苯^ υ瞇为主要成分的热塑性组合物构成。
中国发明专利申请号 ZL200680046075.7 (国际申请 PCT/JP2006/324493 , 国际公 布 WO2007/066742 )揭示了一种金属树脂复合体及其制造方法的相关技术， 其 征 在于， 由铝合金构件和热塑性合成树脂组合物构件形成， 所述铝合金构件是如下构 件： 经过浸渍于选自氨、 胼（联胺）和水溶性胺化合物的一种以上的水溶液的工序， 用电子显微镜观察， 其表面被数均内径为 10 ~ 80nm的凹部覆盖， 所述热塑性合成树 脂组合物构件是如下构件： 经注塑成型而固着于所述铝合金构件的所述表面上， 并 且树脂成分组成中的主要成分为聚酰胺树脂、 次要成分为耐沖击性改良材料。 然而，上述中国发明专利 ZL02805359.1、 ZL200380102886.0、 ZL200380104500.X ZL200680046075.7都是揭示金属与树脂的复合体及其制造方法的相关技术， 而其 各别特征皆在于， 该金属（如铝合金）形状物是经过特殊选择的水溶液（如水溶性 胺化合物一种以上的水溶液） 中浸渍的浸渍工序， 而再以具有特殊选择成分的热塑 性树脂并以注塑成型方式一体地附着在该铝合金形状物的表面上而构成， 换言之， 该复合体的金属 （铝合金）形状物的工序及树脂形状物的成分均已被特殊化限定， 且相对地较为复杂， 使复合体的制作方法及应用受到限制， 不利于该金属壳体的使 用效率及应用范围， 尤其使用特殊选择的水溶液更不符合目前的环保要求， 因此可 视为上述这些金属壳体物品的缺点。
另如国内发明专利申请号 85100575 (公告号 404888 ) "具有优异加工密接性的 高鲜映性树脂被覆金属板" 揭示了一种树脂被覆金属板的相关技术， 其是以金属板 为基板， 至少在该基板的片面上， 由基板側依序层合有涂料层、聚丙烯共聚物 100 - 20重量份和聚丙烯 100 ~ 0重量份构成的 5 - ΙΟΟμπι厚的变性丙烯树脂层、 花样和 /或 全面印刷层、 接着剂层、 5 ~ 100μπι厚的聚酯系树脂薄膜（见其权利要求 1 ); 或由基 板侧依序层合有涂料层、 花样和 /或全面印刷层、 聚丙烯共聚物 100 - 20重量份和聚 丙晞 100 ~ 0重量份构成的 5 ~ ΙΟΟμπι厚的变性丙烯树脂层、 接着剂层、 5 ~ ΙΟΟμπι厚 的聚酯系树脂薄膜（见其权利要求 2 ); 或由基板侧依序层合有涂料层、 聚丙烯共聚 物 100 ~ 20重量份和聚丙烯 100 ~ 0重量份构成之 5 ~ ΙΟΟμιη厚的变性丙烯树脂层、 接 着剂层、 5 ~ 100μιη厚的透明聚酯系树脂薄膜（见其权利要求 3 ); 或由基板側依序层 合有涂料层、 5 ~ 100μηι厚的变性烯烃层、 接着剂层、 5 ~ ΙΟΟμπι厚的透明聚酯系树 脂薄膜者 （权利要求 4 )。 然而， 此发明结构中由基板侧依序层合的树脂被覆层的成 分均已被特殊化限定， 且主要目的是该树脂被覆金属板具有高鲜映性， 相对使该金 属板的外形受到限制， 不利于所制成的金属壳体的应用。
再如国内发明专利申请号 86106332 (公告号 434145 ) "具备较高清晰反射性及 优良工作黏着性的涂覆树脂金属片" 揭示了一种涂覆树脂金属片的相关技术， 其包 括： 作为底层片的金属片， 其粗糙度的算术平均值偏差幅度（Ra )数值介于 0微米 及 10微米之间； 透明软树脂层， 其包括未硬化的混合型态树脂层， 聚酯树脂的涂料 涂覆层， 或聚烯烃树脂； 包括颜料的接着层； 具有两面经过光泽处理的透明树脂薄 膜， 其中至少一个金属片表面被着色层、 软树脂层、 接着层和透明层覆盖， 各层是 从金属片侧到透明树脂薄膜依序覆盖。 然而， 此发明结构中由金属片侧依序层合的
J
树脂被覆层的成分均已被特殊化限定， 且主要目的是该树脂被覆金属板具有高鲜映 性， 相对该金属板的外形受到限制， 不利于所制成的金属壳体的应用。
再如国内发明专利申请号 093110015 (证书号 1280190 ) "电子装置壳体金属板成 型方法及其结构"， 其是针对前述的发明专利申请号 86106332 (公告号 434145 )及 发明专利申请号 85100575 (公告号 404888 ) 加以改进， 其揭示一种设置皮膜层的铝 合金基板的相关技术， 其方法至少包括： 一 "涂布接着剂" 步骤， 是于一由铝合金 所制成的金属基板的至少一側表面涂布一层接着剂， 且该接着剂具有金属粉末； 一 "烘烤加热" 步骤， 加热该涂布接着剂的金属基板， 使该接着剂适当软化； 一 "滚 压" 步骤， 经由加热的滚轮将一皮膜层滚压层合于该接着剂上， 其中该皮膜层是由 至少一聚氯乙烯层、 一接着层、 一聚酯层依序层迭结合而成， 且接着层具有金属粉 末； 一 "冷却成型" 步骤， 使该皮膜层与金属基板得以密着结合。 然而， 此发明结 构中由铝合金金属基板一侧表面所层合的皮膜层的成分是由至少一聚氯乙烯层、 一 接着层、 一聚酯层依序层迭结合而成， 因此该皮膜层已被特殊化限定， 相对使该金 属基板所呈现的外形受到限制，不利于所制成的金属壳体（即电子装置壳体金属板） 的应用。
再如国内新型专利申请号 093210282 (证书号 M261368 ) "电子装置壳体金属板 结构"是前述发明专利申请号 093119015 (证书号 1280190 )中结构的新型专利发明。 然而 ,此发明结构也存在如同其发明专利申请号 093119015的皮膜层已被特殊化限定 的缺点。
再如国内新型专利申请号 097208521 (证书号 M345706 ) "复合金属板结构" 揭 示了包括金属基板、 涂覆于该金属基板并加热软化的复合树脂胶层、 及以一辊轮滚 压层合于该复合树脂胶层上的金属面板而使该金属面板与金属基板密着结合。 然 而， 此发明结构的二外侧面一为金属面板一为金属基板， 故存在二外侧面已被特殊 化限定的缺点。
再如国内新型专利申请号 096215339 (证书号 M328384 ) "环保型贴皮金属结构" 揭示了一贴皮金属结构的相关技术， 其至少包括： 一金属基板； 涂布于前述金属基 板的至少一侧表面并加热使之适当软化的接着剂层； 及由一聚氨酯底层及聚氨酯面 层依序层迭结合而成的皮膜层， 以一滚轮滚压使其层合于前述接着剂层上然后冷 却， 使该皮膜层与金属基板密着结合。 然而， 此发明结构中的皮膜层的成分是由一 聚氨酯底层及聚氨酯面层依序层迭结合而成， 因此该皮膜层已被特殊化界定， 使该 金属基板所呈现的外形或触感相对受到限制， 不利于所制成金属壳体的应用。
综上所述， 复合板材的现有技术中确实存在一些缺点， 本发明主要是针对上述 现有技术的缺点而加以有效解决。 发明内容
本发明的目的在于提供一种金属基板与外饰层结合的复合板材， 其由金属基板 至外饰层依序包含： 一金属基板、 一第一 TPR黏着层、 一第二 TPR黏着层及一外饰 层， 其中：
该金属基板， 是具有适当厚度的金属薄板， 其表面具有数个近乎均匀覆盖的细 凹孔， 该细凹孔是在该金属基板的成型制作过程中在其表面上自然产生的；
该第一 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄 膜构成， 其厚度为 400-500 μπι, 其是通过滚轮或平板的加热加压方式热压贴合在该 金属基板的一侧表面上， 且其部分厚度在热压贴合中渗入该金属基板表面上的所述 数个细凹孔中；
该第二 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄 膜构成， 其厚度为 400-500 μιη, 其贴覆在该外饰层的一侧表面上；
该外饰层， 是一装饰用薄层， 其表面上具有数个近乎均匀覆盖的细孔， 这些细 孔是在该外饰层的成型制作过程中于表面上自然产生的；
其中， 该金属基板与外饰层利用热压贴合工序而相互热压贴合以形成一复合板 材；
其中， 当该金属基板与外饰层在进行热压贴合工序时， 二者之间的该第一 TPR 黏着层与第二 TPR黏着层同时相互热熔结合， 且该第二 TPR黏着层的部分厚度同时 渗透至该外饰层表面上既有的数个细孔中 , 以使外饰层通过该第二 TPR黏着层与第 一 TPR黏着层紧密黏着在金属基板的一侧表面上， 并达成容许深加工而不剥离的黏 着程度。
其中， 该金属基板是铝合金板。
该外饰层是布料层， 其由天然纤维如植物纤维的棉、 麻或动物纤维的毛、 蚕丝 构成， 或由人造纤维如尼龙、 聚酯纤维、 压克力纤维构成。
该外饰层是皮革层， 其由天然皮革如羊皮、 牛皮构成， 或由 PU、 PVC或 PU与 PVC合成皮构成。
该外饰层是由削成薄片状的竹片构成的竹材层。
该外饰层是由削成薄片状的木片构成的木材层。
该第一 TPR黏着层厚度 400-500 μπι ( 10'6m ) 中的 10%部分， 即约 40-50 μπι的厚 度在热压贴合中渗入该金属基板表面上的所述数个细凹孔中。
本发明的另一个目的是提供一种所述复合板材的制法， 包含下列步骤： 提供具有适当厚度的金属基板， 且该金属基板的表面上因其成型制作方法而自 然具有近乎均匀覆盖在其表面上的数个细凹孔；
通过滚轮或平板的加热加压方式， 在该金属基板的一侧表面上热压一层厚度为
400-500 μηι的第一 TPR黏着层， 该 TPR黏着层是由以丁苯嵌段共聚物与碳氢石油树 脂合成的热可塑性橡胶薄膜构成， 并使该第一 TPR黏着层约 10% (约 40-50 μιη ) 的 部分厚度在热压过程中渗透至金属基板表面上既有的数个细凹孔中；
提供具有适当厚度的外饰层， 且该外饰层的表面上因其成型制作工艺而自然具 有近乎均勾覆盖在其表面上的数个细孔；
通过滚轮的加热方式， 在该外饰层的一表面上贴覆厚度为 400-500 μιη ( l(T6m ) 的第二 TPR黏着层， 该 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可 塑性橡胶薄膜构成；
再对上述金属基板及外饰层， 进行一次热压贴合工序， 以使该金属基板与外饰 层通过各表面上所设的第一与第二 TPR黏着层而相互热压贴合， 并使该第二 TPR黏 着层在该热压贴合工序中渗透至该外饰层表面既有的数个细孔中并同时与金属基 板上的第一 TPR黏着层密着结合；
待冷却后， 形成具有金属基板与外饰层的一体式复合板材。
其中， 该金属基板是铝合金板。
该外饰层的材质包含下列组群中的一种： 布料层如由天然或人造纤维构成， 皮 革层如由天然或 PU/PVC合成皮构成， 竹材层由削成薄片状的竹片构成、 或木材层 由削成薄片状的木片构成。
该热压贴合工序进一步包含一烘烤加热工序， 用以对该金属基板表面上所设的 第一 TPR黏着层进行烘烤加热作业， 使该第一 TPR黏着层加热至约 130°C , 使之适当 软化以利于贴合作业。
该热压贴合工序进一步包含一烘烤加热工序， 用以对该外饰层表面上所设的第 二 TPR黏着层进行烘烤加热作业， 以使该第二 TPR黏着层加热至约 130°C， 使之适当 软化以利于贴覆作业。
该热压贴合工序进一步利用加热的滚轮， 其温度保持在约 140°C， 用以将外饰 层通过其表面上的第二 TPR黏着层以滚压层合于该金属基板的第一 TPR黏着层上， 以使外饰层与金属基板密着结合。 本发明的复合板材及其制法， 由于该第二 TPR黏着层可通过该热压贴合工序渗 透至该外饰层表面既有的细孔中并同时与金属基板上的第一 TPR黏着层稳固密着结 合而不易剥离， 使所成型的复合板材可随设计需要而进行深加工成型作业如深沖、 拉伸、 裁切等， 用以制成兼具强度优点及装饰美观优点的壳体形状物， 避免先前技 术中黏着效果及成型质量不佳且外饰层所用材料常相对受限的缺点。
本发明的复合板材及其制法， 由于该外饰层可选择使用布面层、 皮面层或合成 皮面层、 天然或合成树脂纤维面层等， 使该复合板材或所形成的壳体形状物得以具 有各种不同的外观花样和 /或触感， 增加产品外观的多样化及消费者的选择性， 有利 于提高产品的价值性及市场竟争力， 并可避免先前技术中随着外饰层的材料不同即 须另发展一套不同的制备方法及设备才能完成复合板材的困扰， 达成生产效率高、 容易量产化、 可深沖加工且成型质量控管佳之实用效果。 附图说明
图 1是本发明复合板材制备方法的流程示意图；
图 2是本发明复合板材结构的剖面 （放大）示意图；
图 3是利用本发明复合板材经引伸沖压成型加工所形成一壳体形状物的前视立 体示意图；
图 4是图 3的背视立体示意图。
附图标记说明： 1-复合板材； 2-壳体形状物； 10-金属基板； 11-表面； 12-细凹 孔； 20-第一 TPR黏着层； 21-界面； 30-外饰层； 31-表面； 32-细孔； 40-第二 TPR黏 着层； 41-界面； 50-点线。 具体实施方式
以下结合附图， 对本发明上述的和另外的技术特征和优点作更详细的说明。 参考图 1 , 其是本发明的制造方法流程图示意图。 本发明的复合板材 1的制法， 主要包含下列步骤：
提供具有适当厚度的金属基板 10; 该金属基板 10包含且不限制为铝合金薄板， 且该金属基板 10的表面上随一般金属基板的成型制作工艺而自然具有可视为近乎 均匀散布的数个细 KJ孔； ―
于该金属基板 10的至少一侧表面上， 通过滚轮或平板的加热加压方式热压一层 厚度约 400-500 μηι ( μηι= l(T6m )的第一 TPR黏着层 20, 该 TPR是由丁苯嵌段共聚物 与碳氢石油树脂合成的热可塑性橡胶薄膜， 并使该第一 TPR黏着层 20的部分厚度， 如约 10%约 40-50 μηι, 可以渗透至金属基板表面上既有的数个细凹孔中；
提供具有适当厚度的外饰层 30; 该外饰层 30包含但不限制为下列组群中的一 种： 如由天然或人造纤维构成的布料层， 如由天然或 PU/PVC合成皮构成的皮革层， 由削成薄片状的竹片构成的竹材层、 或由削成薄片状的木片构成的木材层等， 且该 外饰层 30的表面上随该外饰层 30的一般成型制作程序而自然具有可视为近乎均匀 散布的数个细孔；
于该外饰层 30的欲结合的表面上， 通过滚轮加热但不加压或只加少许压力的方 式贴覆厚度约 400-500 μπι的第二 TPR黏着层 40, 并使该第二 TPR黏着层 40未渗透至 外饰层表面既有的数个细孔中；
再针对上述金属基板 10及外饰层 30, 进行一次热压贴合工序， 以使该金属基板 10及外饰层 30通过各表面上所设第一与第二 TPR黏着层 20、 40而相互热压贴合， 并 使该第二 TPR黏着层 40可以在该热压贴合工序中渗透至该外饰层 30表面既有的数个 细孔中并同时与金属基板 10上的第一 TPR黏着层 20稳固密着结合；
待冷却后， 即形成具有金属基板 10与外饰层 30的一体式复合板材 1，如图 2所示。 经由本发明的上述制法， 由于该第二 TPR黏着层 40可在该热压贴合工序中渗透 至该外饰层 30表面上既有的数个细孔中并同时与金属基板 10上的第一 TPR黏着层 20 稳固地热融密着结合成一体， 故所制成的复合板材 1可在金属基板 10与外饰层 30之 间的结合保持相当良好的密着性， 且在经实体试验后， 证明足以承受各种不同方式 的后续深加工成型作业如深冲、 拉伸、 裁切等； 因此， 本发明的复合板材 1可随设 计需要进行深加工成型作业， 供用以制成兼具强度优点及装饰美观优点的壳体形状 物 2, 如图 3、 4所示， 从而避免先前技术中黏着效果及成型质量不佳且外饰层所用 材料常相对受限的缺点。
尤其， 本发明的制法与这些现有技术相比较， 本发明的制法更能符合目前的环 保要求。 本发明制法是利用该金属基板 10表面上在其成型制作程序中所自然形成且 近乎均匀散布的数个细凹孔， 以使该第一 TPR黏着层 20的部分厚度可在热压步骤中 直接渗入这些细凹孔中， 因此本发明的方法中并未利用任何特殊的水溶液或任何将 金属基板浸渍在特殊水溶液的相关工序， 以先在金属基板表面上形成或覆盖数个具 有一定程度深度或内径的凹部从而使具有特殊成分的热塑性树脂成型并黏着在该 金属基板的表面上， 如中国专利 ZL02805359.1、 ZL200380102886.0,
ZL200380104500.X及 ZL200680046075.7等现有技术所揭示的相关技术。 上述方法中， 在金属基板 10的表面热压该第一 TPR黏着层 20之前， 可针对该金 属基板 10的表面状态需要， 而先采取一净化处理步骤， 该净化处理步骤包含且不限 制为脱脂、 强力刷洗等， 主要目的在于使该金属基板 10的工作表面保持在一定程度 的洁净状态， 以避免对后续的第一 TPR黏着层 20的热压作业程序产生不良影响， 从 而使该第一 TPR黏着层 20与金属基板 10的表面之间达到良好的紧密接着效果。
上述方法中， 在使外饰层 30与金属基板 10密着结合所使用的热压贴合工序中， 进一步可包含且不限制的下列工序： 如在进行热压贴合工序之前， 先进行一烘烤加 热工序，用以对该金属基板 10的表面上所设的第一 TPR黏着层 20进行烘烤加热作业， 以使该第一 TPR黏着层 20可加热至约 130°C而适当软化 ,以利于与外饰层 30的表面上 所设的第二 TPR黏着层 40进行热压贴合工序； 亦可进一步进行另一烘烤加热工序， 用以对该外饰层 30的表面上所设的第二 TPR黏着层 40进行烘烤加热作业， 以使该第 二 TPR黏着层 40可加热至约 130°C而适当软化,以利于与金属基板 10的表面上所设的 第一 TPR黏着层 20进行热压贴合工序。
上述方法中， 可利用一加热的滚轮来进行该热压贴合工序， 而该滚轮的温度可 保持在约 140°C ,用以将外饰层 30通过第二 TPR黏着层 40而滚压层合于该金属基板 10 的第一 TPR黏着层 20的表面上， 以使外饰层 30与金属基板 10通过第一与第二 TPR黏 着层 20、 40间的熔合特性而形成一体式复合板材 1。
参考图 2, 其是本发明的复合板材 1的结构剖面示意图。 本发明的一体式复合板 材 1的结构依序包含： 一金属基板 10、 一第一 TPR黏着层 20、 一第二 TPR黏着层 40及 一外饰层 30等主要部分。
该金属基板 10是可用以构成一电子装置的壳体形状物 2的金属元材， 该壳体形 状物 2如图 3、 4所示，包含且不限制为计算机（ computer )产品、通讯（ communication ) 产品或消费性（consumer )产品等 3C产品的壳体， 一般是利用质轻强度佳的金属板 如铝合金板； 该金属基板 10的表面 11上基本上具有数个细凹孔 12 (为求明显， 图中 凹孔 12是放大表示） 并可视为近乎均匀散布或覆盖在表面 11上， 而且所述细凹孔 12 是在一般金属基板 10的成型制作工艺中如辗压成型加工而在表面上自然产生的， 并 非是利用任何经过特殊水溶液或任何将金属基板 10浸渍在特殊水溶液的相关工序 而形成。
该第一 TPR黏着层 20是以丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶 薄膜构成， 其材料成分的比例可以不同， 如 TPU.TPE薄膜， 其厚度约 400-500 μιη ( 1μηι= 10'6m ), 其是经由滚轮或平板的加热加压方式热压在该金属基板 10的至少 一侧的表面上而与该金属基板 10结合成一体，而且该第一 TPR黏着层 20的部分厚度 , 如约原厚度的 10%约 40-50 μηι, 可以在热压贴合作业中渗透入金属基板 10的表面 11 上既有的这些数个细凹孔 12中， 通过增加该第一 TPR黏着层 20与该金属基板 10之间 的黏着强度以防在深冲加工中剥离或破损。 而第一 TPR黏着层 20的外側面用界面 21 表示。
该第二 TPR黏着层 40是以丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶 薄膜构成， 其与第一 TPR黏着层 40的材料可完全相同， 或材料成分相同但混合比例 不同， 如 TPU.TPE薄膜； 此外该第二 TPR黏着层 40厚度约 400-500 μπι, 其是通过滚 轮的加热但不加压或只加少许压力的方式贴覆在该外饰层 30的表面 31上， 但在贴覆 作业中， 因滚轮的加热但不加压或只加少许压力， 使该第二 TPR黏着层 40未渗透至 外饰层 30的表面 31上既有的数个细孔 32中， 也就是金属基板 10及外饰层 30在进行热 压贴合工序之前， 该第二 TPR黏着层 40并未渗透至外饰层 30的表面 31上既有的数个 细孔 32中。 而第二 TPR黏着层 40的外侧面用界面 41表示。
此外， 图 3所示的复合板材 1是经过热压贴合工序之后的成型物， 此时该金属基 板 10及外饰层 30已通过第一与第二 TPR黏着层 20、 40而相互热压贴合， 也就是第一 与第二 TPR黏着层 20、 40之间已相互热熔结合， 故图 3中无法再保留或标示第一与第 二 TPR黏着层 20、 40原有的界面 21/ 41， 因此在图 3中另外用两个适当间隔的点线 50 来表示原有的界面 21/ 41之间的熔接状态。
该外饰层 30包含且不限制为下列组群中之一种： 一布料层， 其由天然纤维如植 物纤维的棉、 麻等或动物纤维的羊毛、 蚕丝等， 或人造纤维如尼龙、 聚酯纤维、 压 克力纤维构成； 一皮革层， 其由天然皮或 PU PVC合成皮构成； 一竹材层， 其由削 成薄片状的竹片构成； 或一木材层， 其由削成薄片状的本片构成等； 该外饰层 30可 随使用需要如订购者指定而各别加工，从而具有各种不同的外观花样或触感；此外， 该外饰层 30的表面 31上随着该外饰层 30的成型制作程序而自然具有可视为近乎均 匀散布的数个细孔 32， 如天然或人造纤维的网孔或天然皮的毛细孔。 因此， 当金属 基板 10及外饰层 30在进行热压贴合工序时， 该第二 TPR黏着层 40可同时渗透至外饰 层 30的表面 31上既有的数个细孔 32中， 以使外饰层 30能通过第二 TPR黏着层 40与第 一 TPR黏着层 20而紧密黏着在金属基板 10的一侧表面上， 并达成容许深加工而不剥 离的紧密黏着程度。
现通过以下各实施例 （其中金属基板 10皆为铝合金板， 但外饰层 30为不同材 质）， 进一步说明本发明复合板材 1的结构及其所能达成的作用功效： <实施例 1〉
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μπι; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 整体厚度变为约 360-450μιη;
外饰层 30为以天然纤维如植物纤维的棉、 麻等或动物纤维的羊毛、 蚕丝等所构 成厚度为 0.3mm的布料层， 而其表面上所设的第二 TPR黏着层 40为由丁苯嵌段共聚 物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μιη;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.1mm;
结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 为由 -40°C至 85°C以及 85°C至 -40°C每分钟升温或降温 1 °C且经 4次循环， 以该复合板 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
<实施例 2 >
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μηι; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 厚度变为约 360-450μπι;
外饰层 30为以人造纤维如尼龙、 聚酯纤维、 压克力纤维所构成且厚度为 0.3mm 的布料层， 而其表面上所设的第二 TPR黏着层 40为由丁苯嵌段共聚物与碳氢石油树 脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μπι;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.1mm;
结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
<实施例 3 >
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μιη; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 厚度变为约 360-450μπι;
外饰层 30为以天然皮革羊皮所构成且厚度为 0.4mm的皮革层， 而其表面上所设 的第二 TPR黏着层 40为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜 构成， 厚度约 400-500μηι;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.2mm;
结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 为由 -40°C至 85°C以及 85°C至 -40°C每分钟升温或降温 1 °C且经 4次循环， 以该复合板 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
<实施例 4 >
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μπι; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 厚度变为约 360-450μπι;
外饰层 30为以 PU/PVC合成皮构成且厚度为 0.5mm的皮革层，而其表面上所设的 第二 TPR黏着层 40为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构 成， 厚度约 400-500μιη;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.3 mm;
结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
<实施例 5〉
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μπι; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 厚度变为约 360-450μπι;
外饰层 30为以削成薄片状的竹片构成且厚度为 0.4mm的竹材层， 而其表面上所 设的第二 TPR黏着层 40为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄 膜构成， 厚度约 400-500μιη;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.2mm; 结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 为由 -40°C至 85°C以及 85°C至 -40°C每分钟升温或降温 1°C且经 4次循环， 以该复合板 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
<实施例 6 >
本实施例的复合板材 1包含：
金属基板 10为厚度为 0.8mm的铝合金板， 而其表面上所欲设的第一 TPR黏着层 20为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶薄膜构成， 厚度约 400-500μιη; 而当第一 TPR黏着层 20经滚轮或平板的加热加压方式热压在铝合金板 10上后， 厚度变为约 360-450μιη;
外饰层 30为以削成薄片状的木材薄片构成且厚度为 0.4mm的竹材层， 而其表面 上所设的第二 TPR黏着层 40为由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡 胶薄膜构成， 厚度约 400-500μηι;
经热压贴合工序之后， 所成型的复合板材 1的厚度为 1.2 mm;
结果发现， 本实施例的剥离强度密着性为每平方公分 5公斤， 环境测试密着性 为由 -40°C至 85°C以及 85°C至 -40°C每分钟升温或降温 1 °C且经 4次循环， 以该复合板 材形成的壳体形状物如图 3、 4所示， 其中该外饰层 30与铝合金板 10不剥离。
以上所述仅为本发明的较佳实施例， 对本发明而言仅仅是说明性的， 而非限制 性的。 本专业技术人员理解， 在本发明权利要求所限定的精神和范围内可对其进行 许多改变， 修改， 甚至等效， 但都将落入本发明的保护范围内。

Claims

权利要求
1、 一种金属基板与外饰层结合的复合板材， 其特征在于， 其由金属基板至外 饰层依序包含： 一金属基板、 一第一 TPR黏着层、 一第二 TPR黏着层及一外饰层， 其中：
该金属基板， 是具有适当厚度的金属薄板， 其表面具有数个近乎均勾覆盖的细 凹孔， 这些细凹孔是在该金属基板的成型制作过程中在其表面上自然产生的；
该第一 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶 薄膜构成， 其厚度为 400-500 μπι, 其是通过滚轮或平板的加热加压方式热压贴合在 该金属基板的一侧表面上， 且其部分厚度在热压贴合中渗入该金属基板表面上的所 述数个细凹孔中；
该第二 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡胶 薄膜构成， 其厚度为 400-500 μιη， 其贴覆在该外饰层的一侧表面上；
该外饰层， 是一装饰用薄层， 其表面上具有数个近乎均勾覆盖的细孔， 这些细 孔是在该外饰层的成型制作过程中于表面上自然产生的；
其中， 该金属基板与外饰层利用热压贴合工序而相互热压贴合以形成一复合板 材；
其中， 当该金属基板与外饰层在进行热压贴合工序时， 二者之间的该第一 TPR 黏着层与第二 TPR黏着层同时相互热熔结合， 且该第二 TPR黏着层的部分厚度同 时渗透至该外饰层表面上既有的数个细孔中 ,以使外饰层通过该第二 TPR黏着层与 第一 TPR黏着层紧密黏着在金属基板的一侧表面上，并达成容许深加工而不剥离的 黏着程度。
2、 如权利要求 1所述的复合板材， 其特征在于， 该金属基板是铝合金板。
3、 如权利要求 1 所述的复合板材， 其特征在于， 该外饰层是布料层， 其由天 然纤维如植物纤维的棉、 麻或动物纤维的毛、 蚕丝构成。
4、 如权利要求 1 所述的复合板材， 其特征在于， 该外饰层是布料层， 其由人 造纤维如尼龙、 聚酯纤维、 压克力纤维构成。
5、 如权利要求 1 所述的复合板材， 其特征在于， 该外饰层是皮革层， 其由天 然皮革如羊皮、 牛皮构成。
6、 如权利要求 1所述的复合板材， 其特征在于， 该外饰层是皮革层， 其由 PU、 PVC或 PU与 PVC合成皮构成。
7、 如权利要求 1 所述的复合板材， 其特征在于， 该外饰层是竹材层， 其由削 成薄片状的竹片构成。
8、 如权利要求 1 所述的复合板材， 其特征在于， 该外饰层是木材层， 其由削 成薄片状的木片构成。
9、如权利要求 1所述的复合板材，其特征在于，该第一 TPR黏着层厚度 400-500 μπι中的 10%部分， 即约 40-50 μιη的厚度在热压贴合中渗入该金属基板表面上的所 述数个细凹孔中。
10、 一种金属基板与外饰层结合的复合板材的制法， 其特征在于， 用以制作权 利要求 1-9中任一项所述的复合板材， 包含下列步骤：
提供具有适当厚度的金属基板， 且该金属基板的表面上因其成型制作工艺而自 然具有近乎均勾覆盖在其表面上的数个细凹孔；
通过滚轮或平板的加热加压方式， 在该金属基板的一侧表面上热压一层厚度为 400-500 μπι的第一 TPR黏着层， 该 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树 脂合成的热可塑性橡胶薄膜构成，并使该第一 TPR黏着层约 10%的部分厚度在热压 过程中渗透至金属基板表面上既有的数个细凹孔中；
提供具有适当厚度的外饰层， 且该外饰层的表面上因其成型制作工艺而自然具 有近乎均匀覆盖在其表面上的数个细孔；
通过滚轮的加热方式， 在该外饰层的一表面上贴覆厚度为 400-500 μπι的第二 TPR黏着层，该 TPR黏着层是由丁苯嵌段共聚物与碳氢石油树脂合成的热可塑性橡 胶薄膜构成；
再对上述金属基板及外饰层， 进行一次热压贴合工序， 以使该金属基板与外饰 层通过各表面上所设的第一与第二 TPR黏着层而相互热压贴合， 并使该第二 TPR 黏着层在该热压贴合工序中渗透至该外饰层表面既有的数个细孔中并同时与金属 基板上的第一 TPR黏着层密着结合；
待冷却后， 形成具有金属基板与外饰层的一体式复合板材。
11、如权利要求 10所述的复合板材的制法， 其特征在于， 该金属基板是铝合金 板。
12、 如权利要求 10 所述的复合板材的制法， 其特征在于， 该外饰层的材质包 含下列组群中的一种： 如由天然或人造纤维构成的布料层， 如由天然或 PU/PVC合 成皮构成的皮革层， 由削成薄片状的竹片构成的竹材层、 或由削成薄片状的木片构 成的木材层。
13、 如权利要求 10 所述的复合板材的制法， 其特征在于， 该热压贴合工序进 一步包含一烘烤加热工序，用以对该金属基板表面上所设的第一 TPR黏着层进行烘 烤加热作业，使该第一 TPR黏着层加热至约 130Ό ,使之适当软化以利于贴合作业。
14、 如权利要求 10 .所述的复合板材的制法， 其特征在于， 该热压贴合工序进 一步包含一供烤加热工序，用以对该外饰层表面上所设的第二 TPR黏着层进行供烤 加热作业，以使该第二 TPR黏着层加热至约 130°C ,使之适当软化以利于贴覆作业。
15、 如权利要求 10 所述的复合板材的制法， 其特征在于， 该热压贴合工序进 一步利用加热的滚轮， 其温度保持在约 140Ό , 用以将外饰层通过其表面上的第二 TPR黏着层以滚压层合于该金属基板的第一 TPR黏着层上，以使外饰层与金属基板 密着结合。
PCT/CN2010/000271 2010-03-05 2010-03-05 金属基板与外饰层结合的复合板材及其制造方法 Ceased WO2011106909A1 (zh)

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