COMPOSITE LAYER AND METHOD FOR PRODUCING A COMPONENT FROM A COMPOSITE LAYER

Abstract

A composite layer that has the following features: a first layer which has at least one layer of a first reinforcing material; a second layer comprising at least one layer of a second reinforcing material; and a fixed layer that is arranged between the first layer and the second layer, wherein the fixed layer has a first section, which is a section of the fixed layer protruding from an intermediate layer space formed between the first layer and the second layer, and a second section which is arranged in the intermediate layer space to join the first layer to the second layer; and an injection-molded part that is in a thermoplastic bond with the first section of the solid layer, wherein the base layer is made of thermoplastic polymer material, and where the fixed layer has the same area as at least the first layer or the second layer before the first section has emerged from the space between the layers.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims priority over Chinese patent application number 201420611689.7, filed on October 21, 2014, and Chinese patent application number 201410818092.4, filed on December 24, 2014. The entire contents of these applications are hereby incorporated by reference. BACKGROUND Technical area

[0002] The present disclosure relates to the field of electronics, in particular to a composite layer, an electronic device, and to a method for manufacturing a component from a composite layer. State of the art

[0003] Currently, most electronic devices use composite materials as a housing material to reduce the thickness and weight of the device and to increase the strength of the housing's protection. Generally, the composite layer used is formed by stacking identical layers of reinforcing fibers; however, this structure results in a relatively heavy and costly composite layer, and it cannot be better bonded to an injection-molded material during an overmolding process.

[0004] Composite components with different layers are known, for example, from JP 2010 - 147 377 A, JP 2009 - 173 027 A, EP 2 090 423 A1, US 2007 / 0 238 378 A1, US 2007 / 0 202 314 A1, and US 2004 / 0 263 761 A1.

[0005] JP 2010 - 147 377 A describes a composite layer consisting of several layers of fiber-reinforced materials, such as carbon fiber or glass fiber. Between these layers is a solid intermediate layer that expands under pressure and enables the bonding of the layers.

[0006] JP 2009-173 027 A describes a process for manufacturing a composite material comprising a resin layer and reinforcing fibers. The process involves applying the reinforcing fibers to the resin layer, curing the resin, and shaping it. The structure of the reinforcing fibers is thereby integrated into the resin layer.

[0007] EP 2 090 423 A1 describes a method for producing a composite structure consisting of several layers bonded by a resin matrix. The structure includes reinforcing fibers embedded in the resin layer in a specific arrangement. The method comprises the steps of arranging the fibers, impregnating them with resin, and curing them to create a strong bond. Furthermore, it is proposed to use different fiber types and resin materials to adapt the composite structure for various applications.

[0008] US Patents 2007 / 0 238 378 A1, 2007 / 0 202 314 A1, and 2004 / 0 263 761 A1 describe methods for manufacturing fiber-reinforced composite structures. Fiber material is placed in a mold and impregnated with resin. The resin hardens while the fibers are held in the desired orientation. Pressure and temperature create a stable composite structure. SUMMARY

[0009] Within the scope of this disclosure, a composite layer according to claim 1 is proposed. Furthermore, within the scope of this disclosure, a method for producing a composite layer according to claim 5 is proposed.

[0010] The embodiment of the present disclosure provides a composite layer, an electronic device and a method for manufacturing a component from the composite layer in order to solve at least one aspect of the problems that exist in the prior art, which are that the composite layer is relatively heavy, that the costs are relatively high, and that the composite layer cannot be better joined during the overmolding process with an injection molding material.

[0011] In particular, the technical solutions include the following.

[0012] In one embodiment, a composite layer is provided comprising a first layer, a second layer, and a fixed layer, wherein the first layer comprises at least one layer of a first reinforcing material; wherein the second layer comprises at least one layer of a second reinforcing material; wherein the fixed layer is arranged between the first and second layers, and wherein the fixed layer is configured to protrude from an intermediate layer between the first and second layers.

[0013] In the exemplary embodiment, the first reinforcing material and the second reinforcing material comprise at least one of carbon fiber, glass fiber and Kevlar fiber.

[0014] In the exemplary embodiment, the first layer is formed by stacking at least a first fiber layer and a second fiber layer, wherein a first stacking angle exists between the first fiber layer and the second fiber layer, and wherein the first stacking angle is an angle between the fiber of the first fiber layer and the fiber of the second fiber layer.

[0015] In the exemplary embodiment, the second layer is formed by stacking at least a third fiber layer and a fourth fiber layer, wherein a second stacking angle exists between the third fiber layer and the fourth fiber layer, the second stacking angle being an angle between the fiber of the third fiber layer and the fiber of the fourth fiber layer.

[0016] In a further embodiment, a composite layer is provided comprising: a first layer comprising at least one first layer of a first reinforcing material; a second layer comprising at least one layer of a second reinforcing material; and a fixed layer comprising a first section and a second section; wherein the first section is a section of the fixed layer which protrudes from the interlayer space under pressure, and wherein the second section is arranged in the interlayer space to join the first layer to the second layer.

[0017] In the exemplary embodiment, the composite layer further comprises an injection-molded part that is in thermoplastic connection with the first section of the solid layer.

[0018] In a further embodiment, an electronic device is provided which comprises: a body; a housing having a shape adapted to the body, wherein the housing is formed from the composite layer, the composite layer comprising a first layer, a second layer and a fixed layer, wherein the first layer has at least one layer of a reinforcing material, wherein the second layer has at least one layer of a reinforcing material, and wherein the fixed layer is arranged between the first and second layers;wherein the fixed layer has a first section and a second section, wherein the first section is a section of the fixed layer which protrudes under pressure from an interlayer space formed between the first layer and the second layer, and wherein the second section is arranged in the interlayer space to join the first layer to the second layer.

[0019] In the exemplary embodiment, the housing further comprises a cover layer which is attached to at least one surface of the housing, wherein the cover layer is formed from a material which is sprayed onto the surface of the housing.

[0020] In a further embodiment, a method for manufacturing a component from a composite layer is provided, which includes the following steps: Pressing a raw composite layer from a first thickness to a second thickness in a predetermined shape at a predetermined temperature, such that a solid layer is heated to soften in order to emerge from a space formed between a first layer and a second layer, wherein the first layer has at least one layer of a first reinforcing material, and wherein the second layer has at least one layer of a second reinforcing material; Filling an injection molding material into a cavity between the raw composite layer and the predetermined shape to form the component, with the protruding section of the solid layer being joined with the injection molding material.

[0021] In the exemplary embodiment, the process further comprises the following steps before the raw composite layer is pressed from the first thickness to the second thickness in the predetermined shape: Arranging at least one fiber layer, wherein the fixed layer is arranged on an upper surface of the at least one fiber layer, and wherein at least one fiber layer is then arranged on the fixed layer to form a first composite layer, wherein the fiber layer on a lower surface of the fixed layer is used as the first layer layer and the fiber layer on an upper surface of the fixed layer is used as the second layer layer; and Pressing the first composite layer to form the raw composite layer according to a predetermined condition. The technical effect of the above technical solutions of the present disclosure will be explained in more detail with reference to the detailed embodiments in the description. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic view showing the structure of a composite layer according to an embodiment of the present disclosure; Fig. 2 is another schematic view showing a structure of a composite layer according to an embodiment of the present disclosure; Fig. Figure 3 is a schematic view showing a structure of a fixed layer in the composite layer according to one embodiment of the present disclosure; Fig. Figure 4 is a schematic view showing a connection between the fixed position and an injection-molded part according to an embodiment of the present disclosure; Fig. Figure 5 is a schematic view in which the composite layer is pressed into a predetermined shape according to an embodiment of the present disclosure; Fig. Figure 6 is a schematic view showing the structure of an electronic device according to an embodiment of the present disclosure; Fig. Figure 7 is a schematic view showing the structure of a housing of an electronic device according to an embodiment of the present disclosure; Fig. Figure 8 is a flowchart showing a process for producing a component from the composite layer according to an embodiment of the present disclosure; Fig. Figure 9 is a schematic view in which the composite layer is pressed into a predetermined shape according to an embodiment of the present disclosure to form a first section; Fig. Figure 10 is a schematic view in which the injection-molded part is filled into a cavity according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE EXECUTION FORMS

[0022] The first embodiment: In the embodiment of the present disclosure, a composite layer is provided comprising a first layer, a second layer, and a fixed layer, wherein the first layer comprises at least one layer of a first reinforcing material; wherein the second layer comprises at least one layer of a second reinforcing material; wherein the fixed layer is arranged between the first and second layers, and wherein the fixed layer is configured to protrude from an intermediate space between the first and second layers. In this embodiment of the present disclosure, the composite layer comprises the first layer, the second layer, and the fixed layer, which is arranged between the first and second layers, and the material of the fixed layer can be a thermoplastic polymer, wherein a first surface of the fixed layer contacts the first layer, and wherein a second surface of the fixed layer contacts the second layer; consequently, the composite layer has better stiffness by using the first and second layers.

[0023] Additionally, the overall weight of the composite layer can be reduced, as the solid layer can be a lightweight thermoplastic material. During the overmolding process, the solid layer effectively prevents the injection-molded plastic from penetrating the composite layer, thus preventing the deformation of the layers at the surface of the composite layer caused by permeation. This allows the composite layer to maintain its shape better and improves product quality.

[0024] If the rigidity of the housing is met, the number of layers of reinforcing material required by the first layer and / or the second layer is further reduced, since the solid layer can be a thermoplastic material; consequently, the weight of the housing formed by the composite layer is reduced, and the cost of the housing is also reduced.

[0025] To better understand the technical solution described above, and to more clearly illustrate the objectives and advantages of this disclosure, the technical solution described above, in combination with the accompanying drawings, is explained in more detail below. It is evident that the described embodiments represent only a portion of the embodiments of the technical solution of this disclosure and not all embodiments. Based on the embodiments illustrated in this description, all other embodiments that can be obtained by a person skilled in the art without any creative effort are included within the scope of this disclosure.

[0026] In the embodiments of the present disclosure, the electronic device can be understood as a notebook computer, PAD (tablet computer), mobile phone, etc.; the embodiments of the present disclosure are not limited to these.

[0027] In the embodiments of the present disclosure, the composite layer can be used to manufacture the housing of the electronic device. For example, the composite material is used to manufacture the housing of a mobile phone, tablet computer, or the like. Generally, the housing of the electronic device is primarily used to protect a particular component within the electronic device; secondarily, the lightweight and thinness properties of the electronic device depend on the lightweight and thinness properties of the housing. Consequently, it is becoming increasingly advantageous to reduce the thickness and weight of the housing during the manufacture of the electronic device.

[0028] To ensure the strength and properties relating to the lightweight and thinness of the housing, the housing is generally manufactured from a composite layer, also known as a composite material. A composite material is a solid material consisting of two or more physical materials. In other words, a composite material is formed by combining a matrix material with a reinforcing material. The materials can complement each other in their properties to create a synergistic effect, so that the overall performance of the composite material is better than that of the original combination of composite materials to meet various requirements.The matrix material of the composite material comprises two categories: metallic and non-metallic. Common metallic matrix materials include aluminum, magnesium, copper, titanium, and their alloys, while non-metallic matrix materials mainly include synthetic resin, rubber, ceramics, graphite, carbon, etc. General reinforcing materials further include mainly fiberglass, carbon fiber, boron fiber, aramid fiber, silicon carbide fiber, asbestos fiber, whisker wire, metal wire, tough granules, etc.

[0029] In order to achieve the strength and properties relating to the lightness and thinness of the housing, the embodiment of the present disclosure provides a composite layer that can be used to manufacture the housing of the electronic device. Fig. Figure 1 is a schematic view showing the structure of the composite layer according to the embodiment of the present invention. The composite layer in the embodiment of the present invention comprises a first layer 1, a second layer 2, and a base layer 3.

[0030] In this embodiment of the present disclosure, the first layer 1 can form an outer surface of the housing of the electronic device. The first layer 1 can comprise at least one layer of a first reinforcing material. The first reinforcing material comprises at least one of glass fiber, carbon fiber, Kevlar fiber, and fiber-reinforced plastics (FRP), and the first reinforcing material can also comprise any combination of these fibers, e.g., the combination of carbon fiber and glass fiber. Furthermore, each layer of the reinforcing material forming the first layer 1 can be joined together by hot pressing or bonding. The FRP, which can be thermoset FRP, is a type of plastic that can be cured or that exhibits insoluble or non-melting properties under heat or other conditions, such as phenolic plastics, epoxy plastics, etc.

[0031] Generally, G is prefixed when glass fiber reinforcement is used, such as GFRP, GFRTP; C is prefixed when carbon fiber reinforcement is used; K is prefixed when aramid polyamide fiber reinforcement is used (Kevlar).

[0032] Glass fiber is commonly used in reinforced plastics, and there are many variations. For example, alkali-free glass fiber (E-glass) is a common fiber containing a small proportion of alkali metal oxide, offering superior chemical stability and electronic insulation properties. High-strength glass fiber (S-glass) incorporates compositions such as magnesium aluminum silicate and exhibits strengths 10–50% higher than E-glass. There are also other types of glass fiber produced using various chemical compositions and manufacturing processes, such as high-modulus glass fiber, medium-alkali glass fiber, and high-alkali glass fiber, which will not be discussed individually here.Carbon fiber exhibits high stiffness and excellent corrosion resistance; it is often used in reinforced thermoset plastics; boron fiber is a composite material made of tungsten and boron and has a relatively larger modulus of elasticity; generally, the thickness of a single layer of the reinforcing material is about 0.2 mm.

[0033] The first layer 1 is formed by stacking at least the first fiber layer and the second fiber layer, wherein there is a first stacking angle between the first fiber layer and the second fiber layer, the first stacking angle being an angle between the fiber of the first fiber layer and the fiber of the second fiber layer.

[0034] Examples of compositions for some first layer 1 are described below.

[0035] A first example: The first reinforcing material can be carbon fiber. The first layer (layer 1) can be formed by stacking the first and second carbon fiber layers. These layers can be stacked at a first stacking angle, which is the angle between the carbon fibers of the first and second layers. In other words, after the first layer is in place, the second layer is then positioned to intersect the first. Generally, the first stacking angle can be 60° or 90°, or alternatively, it can be chosen as required to ensure the strength of layer 1.

[0036] A second example: The first reinforcing material can also be a first mixed fiber of carbon fiber and glass fiber, and the ratio of carbon fiber and glass fiber in the first mixed fiber can be adjusted as required, e.g., the ratio can be 5:5 or 6:4 or the like.

[0037] In this example, the first layer 1 can be formed by stacking the first mixed fiber layer and the second mixed fiber layer, where the stacking angle between the first mixed fiber layer and the second mixed fiber layer can also be the first stacking angle of the first example, it is not described further here.

[0038] It is also noted that the first layer 1 can also be formed by stacking the first mixed fiber layer and the first carbon fiber layer; this type of stacking is not described further here.

[0039] A third example: The first reinforcing material can also be glass fiber, and the first layer 1 is formed by stacking the first glass fiber layer and the second glass fiber layer under the first stacking angle.

[0040] It should be noted that the first layer 1 can also be formed by the first glass fiber layer and the first carbon fiber layer, or by the first glass fiber layer and the first mixed fiber layer. The first layer 1 formed by different layers exhibits some differences in strength and weight. For example, if the first layer 1 is formed by two layers of carbon fiber, the strength of the composite layer is relatively high, and the weight of the composite layer is relatively low, although the cost of the composite layer is correspondingly higher. If the first layer 1 is formed by the first mixed fiber layer and the first carbon fiber layer, the strength of the composite layer is also relatively high, but lower than that of pure carbon fiber, and the weight of the composite layer is also relatively low, but heavier than that of pure carbon fiber.If the first layer 1 is formed entirely of glass fibers, the strength of the composite layer is relatively low, and the weight of the composite layer is relatively high, whereas the cost of the composite layer is lower. Consequently, the first layer 1 can be formed in various ways; the specific forming material is not limited in the embodiments of the present disclosure, and in actual applications, the forming material of the first layer 1 can be selected as required, for example, depending on the requirements of manufacturing costs.

[0041] Alternatively, the first layer can be formed by a plurality of fiber layers; the number of fiber layers contained in the first layer is not limited in the embodiments of the present disclosure.

[0042] Similarly, in this embodiment of the present disclosure, the second layer 2 is parallel to the first layer 1; consequently, the first layer 1 and the second layer 2 can form the upper and lower surfaces of the housing, respectively. The second layer 2 comprises at least one layer of the second reinforcing material, which comprises at least one of carbon fiber, glass fiber, or Kevlar fiber. The second layer 2 is formed by stacking at least the third and fourth fiber layers, wherein there is a second stacking angle between the third and fourth fiber layers, the second stacking angle being an angle between the fiber of the third layer and the fiber of the fourth layer. Examples of compositions for some second layers 2 are described below.

[0043] A first example: The second reinforcing material can be carbon fiber. The second layer (layer 2) can be formed by stacking the third and fourth carbon fiber layers. These layers can be stacked at a first stacking angle, which is the angle between the carbon fibers of the third and fourth layers. In other words, after the third layer is in place, the third layer is then positioned so that it intersects with the third layer. Generally, the first stacking angle can be 60° or 90°, or alternatively, it can be chosen as required to ensure the strength of the second layer (layer 2).

[0044] A second example: The second reinforcing material can also be a first mixed fiber of carbon fiber and glass fiber, and the ratio of carbon fiber and glass fiber in the first mixed fiber can be adjusted as required, e.g., the ratio can be 5:5 or 6:4 or the like.

[0045] In this example, the second layer 2 can be formed by the first mixed fiber layer and the second mixed fiber layer, where the stacking angle between the first mixed fiber layer and the second mixed fiber layer can also be the first stacking angle of the first example; it is not described further here.

[0046] Additionally, it is noted that the second layer 2 can also be formed by stacking the first mixed fiber layer and the first carbon fiber layer; this type of stacking is not described further here.

[0047] A third example: The second reinforcing material can also be glass fiber, and the second layer 2 is formed by stacking the third glass fiber layer and the fourth glass fiber layer under the first stacking angle.

[0048] It should be noted that the second layer 2 can also be formed by the third glass fiber layer and the third carbon fiber layer, or by the third glass fiber layer and the first mixed fiber layer. The second layer 2 formed by different layers exhibits some differences in strength and weight. For example, if the second layer 2 is formed by two layers of carbon fiber, the strength of the composite layer is relatively high, and the weight of the composite layer is relatively low, although the cost of the composite layer is correspondingly higher. If the second layer 2 is formed by the first mixed fiber layer and the third carbon fiber layer, the strength of the composite layer is also relatively high, but lower than that of pure carbon fiber, and the weight of the composite layer is also relatively low, but heavier than that of pure carbon fiber.If the second layer 2 is formed entirely of glass fibers, the strength of the composite layer is relatively low, and the weight of the composite layer is relatively high, whereas the cost of the composite layer is relatively low. Consequently, the second layer 2 can be formed in various ways; the specific forming material of the second layer 2 is not limited in the embodiments of the present disclosure, and in actual applications, the forming material of the second layer 2 can be selected as required.

[0049] It is noted that the material forming the first layer (1) does not affect the material forming the second layer. For example, if the first layer (1) is made entirely of carbon fiber, the second layer (2) can consist of a mixed fiber layer and a carbon fiber layer. Consequently, the first layer (1) and the second layer (2) can be customized as required in actual applications.

[0050] Additionally, it should be noted that the first layer 1 and the second layer 2 can also be formed by three material layers, such as by stacking three layers of carbon fiber, by stacking three layers of mixed fiber, by stacking three layers of glass fiber, or the like. Alternatively, the first layer 1 and the second layer 2 can also be formed by one or four material layers; the material and the number of layers forming the first layer 1 and the second layer 2 are not limited in the embodiment of the present disclosure. Alternatively, the composition of the second layer 2 can be entirely the same as that of the first layer 1, or it can be different from that of the first layer 1; this can be adjusted as necessary.

[0051] Furthermore, as in Fig. Figure 1 shows a solid layer positioned between the first layer (1) and the second layer (2). This solid layer can be a thermoplastic material. The thermoplastic material exhibits softening upon heating and hardening upon cooling, and possesses stable chemical properties, retaining its stability regardless of repeated heating and cooling cycles. During the molding process, the material is first softened to allow it to flow through pressurization and heating without inducing any chemical cross-linking. It is then formed in a mold and, after cooling, creates the desired product shape. Generally, the thermoplastic material forming the solid layer (3) can be polyethylene (PE), polyvinyl chloride (PVC), polyamide (PA), polycarbonate (PC), etc.

[0052] In particular, in this embodiment of the present disclosure, the physical layer 3 has a first surface and a second surface, the first surface of which can contact the first layer 1, and the second surface of which can contact the second layer 2. That is, the first surface and the second surface can be the two contact surfaces via which the solid layer 3 contacts the surface layers, and the first layer 1, the second layer 2, and the solid layer 3 are joined by hot pressing or joining, so that the composite layer has good density to increase the stiffness of the formed product, while at the same time reducing the weight of the product, since the weight of the thermoplastic material is low.

[0053] Alternatively, in a general case, the area of ​​the fixed layer 3 is the same as that of the first layer 1 and / or the second layer 2. The first layer 1 and the second layer 2 have an identical area, and the area of ​​the fixed layer 3, which is arranged between the two layers, is the same as this identical area.

[0054] However, during the manufacturing process of the technical product, the first layer 1 and the second layer 2 may have different surface areas due to design or manufacturing requirements. In this case, the surface area of ​​the fixed layer 3 may be the same as that of the first layer 1 or the second layer 2, or it may be different from the surface area of ​​the first layer 1 and the second layer 2. For example, as in Fig. Figure 2 shows the area of ​​the fixed layer being different from the area of ​​the first layer 1 and the second layer 2.

[0055] Furthermore, in the embodiment of the present disclosure, the thickness of the composite layer is controlled between 0.3 mm and 5 mm, and the density of the composite layer is controlled between 0.5 kg / cm². 3 and 5 kg / cm² 3 controlled to ensure the effect of the final product formed by the composite layer.

[0056] Additionally, it should be noted that in the embodiment of the present disclosure, the first layer 1 is parallel to the second layer 2, so that the first layer 1 and the second layer 2 can form the respective upper and lower surfaces of the housing, and the thickness defined by the first layer 1 and the second layer 2 can be the thickness of the housing, for example, 1.2 mm. However, in actual production, the first layer 1 need not be parallel to the second layer 2. For example, if a surface of the fixed layer 3 is an inclined surface, in which case the first layer 1 is not parallel to the second layer 2. Consequently, the relative position between the first layer 1 and the second layer 2 is not limited in the embodiment of the present disclosure.In actual production, the relative position between the first shift position 1 and the second shift position 2 can be adjusted in a timely manner.

[0057] In the embodiment of the present disclosure, the composite layer is formed by the first layer 1, the second layer 2, and the base layer 3, which is arranged between the first layer 1 and the second layer 2. The base layer 3 can be made of thermoplastic material. The first surface of the base layer 3 contacts the first layer 1, and the second surface of the base layer 3 contacts the second layer 2. Consequently, the composite layer is formed in such a way that the first layer 1 and the second layer 2 can be bonded even more closely to the composite layer. Furthermore, the base layer 3, made of plastic material, can also reduce the weight of the entire composite layer.

[0058] Additionally, the solid layer 3, made of plastic material, exhibits better deformation properties compared to foam material. This allows the solid layer 3 to protrude from the space between the first layer 1 and the second layer 2, enabling it to bond with other plastic materials while preventing other plastic materials from filling this space. Consequently, deformation of the composite layer caused by permeation is avoided, and the proportion of end products within the composite layer is increased.

[0059] Additionally, the overall weight of the composite layer can be reduced because the solid layer 3 can be a lightweight thermoplastic material. During the overmolding process, the solid layer 3 effectively prevents the injection mold from penetrating the composite layer, thus avoiding the deformation problem of the layers at the surface of the composite layer caused by permeation. This allows the composite layer to maintain its shape better and increases production quality.

[0060] Additionally, the number of layers of reinforcing material required by the first layer 1 and / or the second layer 2 is reduced if the housing stiffness is met, since the fixed layer 3 can be a thermoplastic material. Consequently, the weight of the housing formed by the composite layer is reduced, and the housing cost is also reduced.

[0061] The second embodiment: This configuration of the present disclosure provides a composite layer. Fig. Figure 3 is a schematic view showing the structure of the composite layer according to a further embodiment of the present disclosure, the composite layer comprising: a first layer 31 having at least one layer of a first reinforcing material, a second layer 32 having at least one layer of a second reinforcing material, and a fixed layer 33 having a first section and a second section, wherein the first section is the section protruding under pressure from the space between the first layer 31 and the second layer 32, and wherein the second section is arranged in the space between the first layer 31 and the second layer 32 to join the first layer 31 to the second layer 32.

[0062] In particular, the first reinforcing material comprises at least one carbon fiber, glass fiber, or Kevlar fiber. The first layer 31 is formed by stacking at least the first fiber layer and the second fiber layer, wherein there is a first stacking angle between the first fiber layer and the second fiber layer, the first stacking angle being an angle between the fiber of the first fiber layer and the fiber of the second fiber layer.

[0063] Alternatively, the second reinforcing material comprises at least one carbon fiber, glass fiber, or Kevlar fiber. The second layer 32 is formed by stacking at least the third fiber layer and the fourth fiber layer, wherein there is a second stacking angle between the third fiber layer and the fourth fiber layer; the second stacking angle is an angle between the fiber of the third fiber layer and the fiber of the fourth fiber layer.

[0064] The specific composition between the first layer 31 and the second layer 32 was described in detail in the first embodiment and will not be further explained here.

[0065] Furthermore, in this embodiment of the invention, the fixed position 33 has the first section and the second section. Fig. Figure 3 is a schematic view showing the structure of the fixed position according to this embodiment of the present disclosure, in Fig. 3 is the first section of the section that emerges under pressure from the interlayer space between the first layer 31 and the second layer 32, the first section being used to thermoplastically bond with other sections.

[0066] The second section is arranged in the space between the first layer 31 and the second layer 32 to join the first layer 31 with the second layer 32.

[0067] In particular, the composite layer is joined to another plastic material by means of the thermoplastic material of the base layer 33. Therefore, it must be arranged in a mold for processing by overmolding. A first pressure and a first temperature are applied via the mold. The first pressure and temperature serve as a first predefined condition. The base layer 33 softens when it reaches the first temperature, and the softened thermoplastic material is stretched out of the interlayer space under the first pressure, with the stretched section forming the first section of the base layer 33. The first temperature is a temperature at which the thermoplastic material can soften; for example, the first temperature can be between 80° and 200°. The actual temperature to be applied can be determined according to the required degree of softness.The first temperature can be set according to the required thickness of the composite layer, for example if the thickness of the composite layer is 1 mm and the thickness of the composite layer is to be pressed to 0.8 mm, then the first pressure can be set accordingly.

[0068] It is understood that the section remaining between the first layer 31 and the second layer 32 is used as the second section.

[0069] Alternatively, the composite layer exhibits in Fig. Figure 4 of the embodiment of the present invention further shows an injection-molded part 40 which is connected to the first section of the fixed position 33. The injection-molded part 40 is used to create a thermoplastic connection with another part of the electronic device or to provide a position for attaching a fastening screw. It should be noted that the injection-molded part 40 can be made of at least one of synthetic resin, plastic, or mixed materials of fiber and synthetic resin or plastic.

[0070] Especially in a Fig. In the embodiment shown in Figure 5 of the present disclosure, number 50 designates a mold, number 52 designates the injection-molded part, and number 51 designates the first section of the fixed position 3. The dashed arrow in Fig. 5 denotes the mold clamping force exerted on the composite layer. In this case, when the temperature in the mold is increased to the first temperature, the fixed layer 33, which is arranged between the first layer 31 and the second layer 32, softens. Then the softened thermoplastic material is stretched out of the interlayer space, thus extending the first section of the fixed layer 33 into Fig. 5 formed.

[0071] After the first section is extruded, the molten plastic material is poured into the cavity of the mold, consequently forming the injection-molded part 40 in the cavity of the mold. Fig. 5. The thickness of the injection-molded part 40 is exactly the same as the thickness of the composite layer, but in actual production, the thickness of the injection-molded part 40 can differ from the thickness of the composite layer. In other words, the thickness of the injection-molded part 40 can be greater or less than the thickness of the composite layer, depending on the product. The shape of the injection-molded part 40 can also be adapted as required. In this embodiment of the present invention, the injection-molded part 40 is not limited to the dimensions shown in the illustration. Fig. The structure shown in Figure 5 is limited. The molded injection-molded part 40 can be used to achieve a thermoplastic connection with other parts of the electronic device, or to provide a location for a fastening device such as a fastening screw.

[0072] In the actual application process, to further increase the strength of the product using the composite layer, a protective layer can also be sprayed onto the first upper surface of the first layer 31 and / or the second outer surface of the second layer 32 to improve the properties of the housing, such as water resistance, insulation, and wear resistance. The first outer surface is a surface of the first layer 31 that is parallel to, but does not contact, the first surface of the base layer 33; the second outer surface is a surface of the second layer 32 that is parallel to, but does not contact, the second surface of the base layer 33.

[0073] In this embodiment of the present disclosure, the softened solid layer 33 can form the first section that emerges from the space between the first layer and the second layer, so that it is joined to the injection-molded part 40 formed by the plastic injected into the cavity of the mold, since the solid layer 33 of the composite layer is the thermoplastic plastic, consequently a good shaping effect is given in the manufacturing process of the product utilizing the composite layer, and the product quality is improved.

[0074] It should be noted that in this embodiment of the present disclosure, the thickness of the composite layer is controlled between 0.3 mm and 5 mm, and the density of the composite layer is controlled between 0.5 kg / cm³. 3 and 5 kg / cm² 3 It is controlled. Consequently, it is ensured that the composite layer can be used in different devices.

[0075] In this embodiment according to the present disclosure, a composite layer is provided, the composite layer having the first layer 31, the second layer 32, and the fixed layer 33. The physical layer 33 has the first section and the second section, wherein the first section is a section of the fixed layer that protrudes from the space between the first layer 31 and the second layer 32 under pressure, and wherein the second section is arranged in the space between the first layer 31 and the second layer 32. In other words, in this embodiment of the present disclosure, the first section of the fixed layer 33 extends from the space between the layers; consequently, the first section can be joined even more closely to the injection-molded part 40.

[0076] Additionally, because of the extended first section of the solid layer 33, the injection-molded part 40 will not penetrate into the interlayer space between the first layer 31 and the second layer 32 when the injection-molded material 40 is filled into the mold 50. Consequently, the deformation of the composite layer caused by the injection-molded material 40 penetrating into the interlayer space is avoided, therefore the proportion of the final composite layer products is increased and the product quality is improved.

[0077] The third embodiment: Based on the same inventive concept, this embodiment of the present disclosure further provides an electronic device. Fig. Figure 6 is a schematic view showing the structure of the electronic device according to this embodiment of the present disclosure, wherein the electronic device has a body 61 and a housing 62.

[0078] The body 61 can contain the main components of the electronic device; for example, the body 61 can contain a processor, a heat sink, a signal emitter, a display unit, and the like. The casing 62 can be a housing that covers the outer surface of the body 61, such as the casing of a mobile phone, a notebook computer, and the like. Generally, the casing 62 has a shape adapted to the shape of the body 61 to achieve a better embedded fit with the body; consequently, the components inside the body 61 are protected, and the electronic device is better protected.

[0079] In particular, the housing 62 is formed from the composite layer, and the composite layer (as in Fig. Figure 3 shows the first layer 31, the second layer 32 and the fixed layer 33, which is arranged between the first layer 31 and the second layer 32.

[0080] The fixed layer 33 has the first section and the second section, wherein the first section is the section that protrudes under pressure from the interlayer space between the first layer 31 and the second layer 32, and the second section is arranged in the interlayer space between the first layer 31 and the second layer 32 to join the first layer 31 with the second layer 32.

[0081] The composite layer can be formed by the first layer 31, the second layer 32, and the base layer 33 by means of hot pressing or a joining process; such a composite layer can be a sandwich layer of a composite material. The material of the base layer 33 can be a thermoplastic polymer.

[0082] In the actual manufacturing process, the actual number of layers of the reinforcing material used by the first layer 31 and / or the second layer 32 can be determined according to the expected hardness and weight of the housing, so that housings 62 can be obtained that have different hardnesses and weights, consequently the housing 62 can be used to be adapted to different types of electronic devices.

[0083] In particular, the first reinforcing material of the first layer 31 and the second reinforcing material of the second layer 32 can comprise at least one of carbon fiber, glass fiber, Kevlar fiber, or fiber-reinforced plastics. Typically, the thickness of each layer of reinforcing material is less than 0.2 mm, so the thickness of the housing can be within the range of 0.5 mm to 1.5 mm. Alternatively, if higher hardness and improved properties regarding lightness and thinness are required, the housing can have a thickness of 1.2 mm. In this case, the first layer and the second layer can each use two layers of reinforcing fiber, and the solid layer can be filled into the space between the first and second layers, with a gap of 0.4 mm between the first and second layers.

[0084] Furthermore, the first layer 31 is formed by stacking at least the first and second fiber layers, and the second layer 32 is formed by stacking at least the third and fourth fiber layers. The first and second fiber layers are stacked at a first stacking angle, where the first stacking angle is an angle between the fiber of the first layer and the fiber of the second layer. The third and fourth fiber layers are stacked at a second stacking angle, where the second stacking angle is an angle between the fiber of the third layer and the fiber of the fourth layer. The first and second stacking angles do not affect each other; that is, they can be the same or different.

[0085] In addition, the specific composition of the first layer 31 and the second layer 32 was described in detail in the first embodiment; this will not be explained further here.

[0086] Furthermore, in this form of the revelation, position 33 includes the first section and the second section, in particular as in Fig. Figure 3 shows the first section being the section that emerges under pressure from the interlayer space between the first layer 31 and the second layer 32; the first section is used to thermoplastically bond with the injection-molded part 40 (as shown in Figure 3). Fig. 4 shown).

[0087] The second section is arranged in the space between the first layer 31 and the second layer 32 to connect the first layer 31 with the second layer 32.

[0088] In particular, the composite layer must be arranged in a mold for processing by overmolding, since the composite layer is joined with other plastic materials by a thermoplastic material in the fixed layer 33, wherein a first pressure and temperature are applied through the mold, wherein the fixed layer 33 is softened when a certain temperature is reached, and wherein the softened thermoplastic material is stretched out of the interlayer space under the first pressure, forming the first section of the fixed layer 33.

[0089] Obviously, the section remaining between the first layer 31 and the second layer 32 is used as the second section.

[0090] Alternatively, in the embodiment of the present disclosure, the housing 62 has, as shown in Fig. Figure 4 of the first embodiment shows an injection-molded part 40 which connects to the first section of the fixed position 33, wherein the injection-molded part 40 is used to achieve a thermoplastic connection with other parts of the electronic device or to provide a position for attaching a mounting screw. Typically, the injection-molded part can form part of the housing 62, such as a corner, an edge seam, a snap-fit ​​structure, or the like.

[0091] In the actual application process, the housing 62 of the electronic device further comprises, in order to improve the strength and appearance of the housing 62, protective layers applied to at least one surface of the housing 62, wherein the protective layer is formed by a material that is sprayed onto the surfaces of the housing 62. In particular, a protective layer is sprayed onto the first outer surface and / or the second outer surface of the composite layer used to form the housing 62 in order to improve the properties of the housing, such as water resistance, insulation, and wear resistance. The first outer surface is a surface of the first layer 31 that is parallel to the first surface but does not contact it; the second outer surface is a surface of the second layer 32 that is parallel to the second surface but does not contact it.

[0092] In this embodiment of the present disclosure, the softened base layer 33, since the base layer 33 of the composite layer is the thermoplastic polymer, can form the first section during the overmolding process, such that the base layer 33 is joined with the injection-molded part 40, which is formed by the polymer injected into the cavity of the mold. Consequently, there is a good shaping effect during the process of manufacturing the product using the composite layer, and the quality of the product is improved.

[0093] Furthermore, it Fig. Figure 7 shows a schematic structural view, which illustrates that the housing 62 is fixed to the body 61 of the device in the embodiment of the present disclosure. Fig. 7 is a section with a lighter color, a section of the housing 62 corresponding to the composite layer, and a section with a darker color is a section of the housing 61 of the electronic device, wherein one section inside the white lined box is an area of ​​the composite layer in flush connection with the body, another section where the composite layer contacts the body 61 is an area of ​​an overlap connection.

[0094] It should be noted that the flush connection area is an area where the injection-molded part 40 of the composite layer is in direct thermoplastic contact with the plastic material of the body 61. The section with the lighter color, embedded within the darker-colored sections, shows an effect on the top view of the section formed after the first section of the composite layer bonds with the injection-molded part 40.

[0095] The area of ​​an overlap joint is a section of the composite layer that is in direct contact with the plastic material of body 61. It should be noted that the in Fig. The structure shown in Figure 7 is merely one type of structure in actual manufacturing, and the area of ​​a flush connection and the area of ​​an overlap connection of the composite layer may be designed according to different requirements in actual manufacturing.

[0096] In this embodiment according to the present disclosure, an electronic device is provided, wherein the housing 62 of the electronic device comprises the first layer 31, the second layer 32, and the fixed layer 33, which is arranged between the first layer 31 and the second layer 32. Since the fixed layer 33 is a thermoplastic material that can be softened by heat, if the hardness of the housing 62 is satisfied, the number of layers of reinforcing material required by the first layer 31 and / or the second layer 32 can be reduced, and since the thermoplastic material has a low weight, consequently the weight of the housing 62 formed by the composite layer can be reduced, and the cost of the housing 62 can also be reduced.

[0097] The fourth embodiment: A method for producing a component from the composite layer is provided in this embodiment of the present disclosure, Fig. Figure 8 is a flowchart showing the process according to the embodiment of the present disclosure, which includes: S801, the raw composite layer is pressed from a first thickness to a second thickness in a predetermined shape and at a predetermined temperature;

[0098] Before the raw composite layer is pressed in a predetermined shape from a first thickness to a second thickness, the process further comprises: arranging at least one fiber layer, and arranging the fixed layer on the upper surface of the arranged at least one fiber layer, and then arranging at least one fiber layer on the upper surface of the fixed layer, such that a first composite layer is formed, as in Fig. 1 shown. The first composite layer is pressed into the raw composite layer according to a predetermined condition.

[0099] In this embodiment of the present disclosure, the first layer is formed by stacking at least the first fiber layer and the second fiber layer, wherein a first stacking angle is formed between the first fiber layer and the second fiber layer, the first stacking angle being an angle between the fiber of the first fiber layer and the fiber of the second fiber layer. In short, the fiber layers are stacked crosswise. Likewise, the second layer is formed by stacking at least the third fiber layer and the fourth fiber layer, wherein a second stacking angle is formed between the third fiber layer and the fourth fiber layer, the second stacking angle being an angle between the fiber of the third fiber layer and the fiber of the fourth fiber layer.

[0100] Simply put, if multiple fiber layers are arranged—for example, if two fiber layers are arranged first—a thinner layer of plastic can be coated onto the top surface of the first fiber layer after it is in place, and then the second fiber layer is arranged. The plastic layer between each fiber layer creates a better bond between them. Pressing is used to achieve this better bond between each fiber layer and the plastic, thus ensuring the strength of both the first and second layers.

[0101] The first layer can be made entirely of plastic fiber, or can be made of a mixture of plastic fiber and glass fiber, or can also be made entirely of glass fiber; the specific composition of the first and second layers has been described in detail in the first embodiment and will not be further elaborated here.

[0102] In general, the first and second layers can be pressed to a density of approximately 0.2 mm to ensure the strength of the first layer while minimizing its weight. This ensures both the quality and weight of the first and second layers, allowing them to be made lighter and thinner.

[0103] After the first and second layers are formed, the first layer, the base layer, and the second layer are stacked in an orderly fashion. It should be noted that the base layer is sandwiched between the first and second layers. The base layer can be a thermoplastic material. This thermoplastic material exhibits softening upon heating and hardening upon cooling, and has stable chemical properties; in particular, it retains its stable properties regardless of how often it is heated and cooled. During the molding process, the material is first softened to allow it to flow through pressurization and heating without generating any chemical cross-linking. It is then formed in a mold and, after cooling, forms the required product with the specified shape.In general, the thermoplastic material that forms the base layer can be polyethylene (PE), polyvinyl chloride (PVC), polyamide (PA), polycarbonate (PC), etc.

[0104] Alternatively, the thickness of the solid layer is approximately 1.1 mm, and this thickness can be changed in the specific manufacturing process.

[0105] After the first layer, the base layer and the second layer are stacked, the first composite layer is formed, whereby the composite layer can be cut to a suitable size according to the required design, and whereby the final raw composite layer is formed, after which the composite layer is arranged in the specified shape.

[0106] The thickness of this final composite layer is generally within a range of 0.3-5 mm, and its density is within a range of 0.5 kg / cm³. 3 -5 kg / cm 3 .

[0107] Furthermore, the specified shape is a body that has a recess of a certain depth, wherein the composite layer is placed in the recess of the specified shape, the width of the recess of the specified shape being greater than the width of the composite layer, and the depth of the recess being less than the thickness of the composite layer. In other words, a cavity exists in the recess, and the composite layer is higher than the recess in the specified shape after the composite layer is placed in the recess of the specified shape.

[0108] To heat the interlayer between the first and second layers and soften it, the temperature in the mold must be a specific temperature so that the interlayer of the composite layer, made of plastic material, softens, but the interlayer itself will not melt below the specified temperature. For example, if the interlayer is made of plastic material, the specified temperature is generally 80°C.

[0109] It should be noted that if the substrate is not made of plastic material, the specified temperature is the temperature at which the material softens.

[0110] After the solid layer is heated to the specified temperature, the specified pressure is applied to both the upper and lower surfaces of the specified mold. Since the solid layer is softened between the first and second layers, it is stretched out of the space between the two layers after the specified pressure is applied, so that the structure is formed as shown. Fig. 9 is shown being formed. Fig. 9. The softened plastic material emerges from the space between the first layer and the second layer.

[0111] Since the thickness of the raw composite layer is greater than the depth of the recess of the specified mold, the raw composite layer is pressed to a depth that is the same as the recess depth during pressing. In other words, the raw composite layer is pressed from a first thickness to a second thickness. In this embodiment of the previous disclosure, the difference between the first thickness and the second thickness comprises any value between 0.01 mm and 3.0 mm.

[0112] For example, the thickness of the raw composite layer is 1.5 mm and the depth of the recess of the specified mold is 1.3 mm, so that the composite layer is 0.2 mm higher than the recess after it is placed in the recess of the specified mold. Since the width of the recess of the specified mold is greater than the width of the composite layer, the 0.2 mm thick plastic material is pushed out of the space between the first and second layers after the specified pressure is applied to the raw composite layer, so that the structure is as shown in Fig. 9 is shown.

[0113] S802, the injection molding material, is filled into the cavity between the raw composite layer and the predetermined shape, consequently the component is formed.

[0114] In S801, the raw composite layer was pressed into the structure that is in Fig. Figure 9 shows that in this case, the first section of the composite layer protrudes from the interlayer space formed between the first and second layers. Since the width of the recess of the mold is greater than the width of the composite layer, even after the first section has formed following mold pressing, a cavity remains around the first section. Molten plastic or polymer material is then poured into this recess through a channel located on the mold. In this way, the first section and the plastic or polymer material poured into the recess are thermoplastically bonded together, resulting in the structure shown in Figure 9. Fig.Figure 10 shows the formation. After the base layer and the filled plastic material have cooled, the resulting end product is the component provided by this embodiment of the invention.

[0115] Furthermore, in one embodiment of the present invention, after the component has been formed, a protective material can be sprayed onto at least one outer surface of the component.

[0116] To improve the component's hardness, wear resistance, water resistance, and similar properties, a layer of protective material, such as a colored coating, can be sprayed onto the outer surface of the pressed component. This can result in improved wear resistance, water resistance, and therefore also an enhanced appearance of the component.

[0117] Alternatively, in one embodiment of the present disclosure, the formed component can also be fine-machined to produce a component that is attached to an electronic device; for example, the fine-machining can include grinding, polishing the component or similar additional processes, which are not explained in detail here.

[0118] In general, a method for forming a component from the composite layer according to one embodiment of the invention is provided. The method comprises the following steps: pressing a raw composite layer from a first thickness to a second thickness in a predetermined mold at a predetermined temperature, then filling a cavity between the raw composite layer and the predetermined mold with injection molding material, and forming the required component. Since the base layer is a lightweight thermoplastic, the overall weight of the composite layer can be reduced.During an overmolding process, the solid layer can effectively prevent the injection-molded plastic from penetrating the composite layer and consequently avoid the deformation problem of the layer layers on the surfaces of the composite layer caused by penetration (permeation), so that the composite layer can maintain a better shape and the product quality is increased.

Claims

[1] A composite layer that has the following features: a first layer which has at least one layer of a first reinforcing material; a second layer comprising at least one layer of a second reinforcing material; and a fixed layer that is arranged between the first layer and the second layer, wherein the fixed layer has a first section, which is a section of the fixed layer protruding from an intermediate layer space formed between the first layer and the second layer, and a second section which is arranged in the intermediate layer space to join the first layer to the second layer; and an injection-molded part that is in a thermoplastic bond with the first section of the solid layer, wherein the base layer is made of thermoplastic polymer material, and where the fixed layer has the same area as at least the first layer or the second layer before the first section has emerged from the space between the layers. [2] The composite layer according to claim 1, wherein the first reinforcing material and the second reinforcing material comprise at least one of carbon fiber, glass fiber and Kevlar fiber. [3] The composite layer according to claim 1 or 2, wherein the first layer is formed by stacking at least a first fiber layer and a second fiber layer, wherein a first stacking angle exists between the first fiber layer and the second fiber layer, and wherein the first stacking angle is an angle between the fiber of the first fiber layer and the fiber of the second fiber layer. [4] The composite layer according to any one of claims 1 to 3, wherein the second layer is formed by stacking at least a third fiber layer and a fourth fiber layer, wherein a second stacking angle is present between the third fiber layer and the fourth fiber layer, wherein the second stacking angle is an angle between the fiber of the third fiber layer and the fiber of the fourth fiber layer. [5] A method for producing a component from a composite layer according to any one of claims 1 to 4 and an injection-molded part associated therewith, wherein the method comprises the following steps: Pressing a raw composite layer from a first thickness to a second thickness in a predetermined shape at a predetermined temperature, such that a solid layer is heated to soften in order to emerge from an intermediate space formed between a first layer and a second layer, wherein the first layer has at least one layer of a first reinforcing material and the second layer has at least one layer of a second reinforcing material; Pouring an injection molding material into a cavity between the raw composite layer and a predetermined shape to form the component, wherein the protruding section of the base layer is joined with the injection molding material and the base layer material is a thermoplastic polymer material; wherein the process further comprises the following steps before the raw composite layer is pressed in the predetermined shape from the first thickness to the second thickness: Arranging at least one fiber layer, wherein the fixed layer is arranged on an upper surface of the at least one fiber layer, and wherein at least one fiber layer is then arranged on the fixed layer to form a first composite layer, wherein the fiber layer on a lower surface of the fixed layer is used as the first layer layer and the fiber layer on an upper surface of the fixed layer is used as the second layer layer; and Pressing the first composite layer to form the raw composite layer according to a predetermined condition.

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