Method for manufacturing a kevlar protective shell with shock absorbing structure

Abstract

The application discloses a preparation method of a Kevlar protective shell with a damping structure and relates to the technical field of Kevlar protective shells. The preparation method comprises the following steps: S1, placing cut Kevlar pieces and organic silica gel in a forming mold, wherein one outer side of the organic silica gel is provided with a layer of TPU, and the outer side of the organic silica gel provided with the TPU is attached to the Kevlar; S2, the forming mold is firstly subjected to hot press forming, so that the Kevlar is bonded to the organic silica gel through the TPU, and a main body formed by the Kevlar and the organic silica gel is pressed into a protective shell semi-product with a back plate and a frame, the organic silica gel forms an inner side surface of the protective shell semi-product, and the Kevlar forms an outer side surface of the protective shell semi-product; S3, the forming mold is then subjected to cooling, so that the protective shell semi-product is cooled and formed; and S4, the frame of the protective shell semi-product is subjected to edge rolling through an edge rolling machine, so that the protective shell is obtained, the corner is smooth, the protective shell has a damping structure, and the preparation process is more simple and convenient.

Description

Technical Field

[0001] This invention relates to the field of Kevlar protective shell manufacturing technology, specifically a method for manufacturing a Kevlar protective shell with a shock-absorbing structure. Background Technology

[0002] Traditionally, when using Kevlar as a phone case, multiple sheets of Kevlar are laid on a pre-made phone mold, and adhesive is applied between the sheets to bond them together and form the shape of the phone case. Alternatively, the Kevlar is placed directly into the mold cavity of a hot press, and the phone case is formed using the hot press. Finally, laser cutting is used to trim and finish the case.

[0003] Currently, when used as a mobile phone case, it is usually required that the mobile phone case has a back panel and a frame. Most of them also need the edges of the frame to be rolled. This kind of mobile phone case with a frame and rolled edges is made of Kevlar sheet material. The main body of the Kevlar sheet material serves as the back panel of the mobile phone case. It is first bent to obtain the frame, and then bent again to obtain the rolled edge.

[0004] This type of mobile phone case with a frame and rolled edges, prepared using the traditional Kevlar mobile phone case manufacturing method described above, has the following characteristics:

[0005] (a) The problem of corners not being smooth enough;

[0006] (ii) The prepared mobile phone case only has Kevlar as protection and lacks shock absorption structure. Although the impact object is not likely to pierce the mobile phone case and thus damage the mobile phone when it is impacted, the huge impact force can be transmitted to the mobile phone, which can easily cause the internal electrical components of the mobile phone to be damaged or loosened.

[0007] (iii) Kevlar phone cases are relatively difficult to remove once installed. This is mainly because Kevlar itself has a certain degree of hardness. Once it's on the phone, it's difficult to expand the Kevlar; it can only form certain shapes on the phone case. Figure 1 The auxiliary notch shown makes it easier to expand, but due to the hardness of Kevlar itself, expansion is still quite difficult, and it is difficult to remove.

[0008] To address the first two issues, Chinese invention application No. 202110311754.9, entitled "A Molding Process for a Kevlar Mobile Phone Case with Built-in Magsafe Magnet," proposes a molding process including the following steps:

[0009] (1) Cutting: Cut the Kevlar-impregnated fabric into the required size for the mobile phone case, namely the outer layer, the middle layer, and the inner layer. The middle layer is cut to reserve the required shape and holes for the magnet module.

[0010] (2) Applied fabric / wrapped material: Cut the Kevlar-impregnated fabric obtained in step (1) into slices, stack them in sequence and cover them with an outer silicone sleeve;

[0011] (3) Molding: The Kevlar fabric assembly with the outer silicone sleeve obtained in step (2) is put into an aluminum foil bag, the air in the bag is removed and then sealed. It is then placed in a vacuum heating tank and molded under high temperature and high pressure for 100-140 minutes. After that, the outer silicone sleeve is removed.

[0012] (4) Cutting: The Kevlar mobile phone case blank obtained in step (3) is laser-cut to obtain the required shape, and then removed from the aluminum core mold of the mobile phone case for packaging and transportation.

[0013] (5) Surface treatment: The cut-out mobile phone case material obtained in step (4) is subjected to continuous spray painting and polishing for surface treatment, and then cleaned, inspected, packaged and stored.

[0014] Furthermore, the specific steps for laminating the Kevlar-impregnated fabric slices in step (2) are as follows:

[0015] (1) Slice the inner Kevlar-impregnated fabric and lay it flat.

[0016] (2) Lay the slices of Kevlar-impregnated fabric in the middle interlayer on the inner surface layer;

[0017] (3) Place the high-temperature Magsafe magnet module according to the pre-reserved holes on the Kevlar-impregnated fabric slice in the middle interlayer;

[0018] (4) Lay the outer layer Kevlar-impregnated fabric slices on the middle interlayer Kevlar-impregnated fabric slices;

[0019] (5) Lay the folded Kevlar fabric on the aluminum core mold of the phone case that wraps the inner silicone sleeve, arrange and position it, and then put on the outer silicone sleeve.

[0020] The inner silicone sleeve allows the Kevlar laminated fabric to be elastically supported from the inside when bent, making the corners of the Kevlar laminated fabric smoother. In the finished phone case, the inner silicone sleeve is integrated with the Kevlar laminated fabric. When the Kevlar laminated fabric is impacted during use, the inner silicone sleeve can absorb some of the energy, providing shock absorption for the phone.

[0021] However, to complete the processing of this Kevlar phone case, in addition to the generally required material preparation and surface treatment steps, the processing technology proposed in this invention requires: 1) first placing the inner silicone sleeve on the aluminum core mold of the phone case; 2) laying the Kevlar laminated fabric on the aluminum core mold of the phone case that wraps the inner silicone sleeve; 3) after arranging and positioning, putting on the outer silicone sleeve; 4) putting the obtained Kevlar laminated fabric assembly with the outer silicone sleeve on into an aluminum foil bag, evacuating the air from the bag and sealing it, and placing it into a vacuum heating tank; 5) after high temperature and high pressure molding for 100-140 minutes, taking it out and removing the outer silicone sleeve.

[0022] Although the Kevlar phone cases produced by this method can solve the problems of smooth cornering and shock absorption for the phone, the manufacturing process is relatively complex and requires a lot of manual labor. Summary of the Invention

[0023] To overcome the shortcomings mentioned above, this invention aims to provide a method for preparing a Kevlar protective case with a shock-absorbing structure that features smooth cornering, easy removal from mobile phones, and a simpler manufacturing process.

[0024] To achieve the above objectives, the present invention provides the following technical solution: a method for preparing a Kevlar protective shell with a shock-absorbing structure, the method comprising:

[0025] S1. Place the cut Kevlar sheet and silicone into the molding mold, wherein one of the outer sides of the silicone has a layer of TPU, and the outer side of the silicone with TPU is attached to the Kevlar.

[0026] S2. The molding die first performs hot pressing molding, so that Kevlar is bonded to silicone through TPU, and the main body formed by Kevlar and silicone is pressed into a protective shell semi-finished product with a back plate and a frame. The silicone forms the inner surface of the protective shell semi-finished product, and the Kevlar forms the outer surface of the protective shell semi-finished product.

[0027] S3. The mold is then cooled to allow the protective shell semi-finished product to cool and solidify.

[0028] S4. The edge of the protective shell semi-finished product is rolled by an edge rolling machine to obtain the protective shell.

[0029] As a further aspect of the present invention: in step S3, the forming mold is cooled and formed without opening the mold after hot pressing by its cooling system.

[0030] As a further aspect of the present invention: the thickness of the Kevlar is 0.5mm-0.7mm, the thickness of the silicone is 0.2mm-0.4mm, and the thickness of the TPU is 0.02mm-0.03mm.

[0031] As a further aspect of the present invention: during hot pressing, the heating temperature is 130℃-150℃, the heating time is 45s-55s, and the pressure of the forming mold is 1.3 tons-1.5 tons.

[0032] As a further aspect of the present invention: the thickness of the Kevlar is 0.6mm, the thickness of the silicone is 0.3mm, and the thickness of the TPU is 0.025mm; during hot pressing, the heating temperature is 150°C, the heating time is 50s, and the pressure of the molding die is 1.4 tons.

[0033] As a further aspect of the present invention: during cooling and molding, the molding die is kept under pressure and cooled.

[0034] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0036] Figure 1 This is a structural diagram of a Kevlar phone case with auxiliary notches;

[0037] Figure 2 This is a flowchart of the method of the present invention;

[0038] Figure 3 This is a structural cross-sectional view of the molding die used in this invention;

[0039] Figure 4 This is a structural cross-sectional view of the edge-rolling machine used in this invention. Detailed Implementation

[0040] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0041] Please see Figure 2-4 A method for preparing a Kevlar protective shell with a shock-absorbing structure, the method including...

[0042] S1. Place the cut Kevlar sheet and silicone into the molding mold, wherein one of the outer sides of the silicone has a layer of TPU, and the outer side of the silicone with TPU is attached to the Kevlar.

[0043] S2. The molding die first performs hot pressing molding, so that Kevlar is bonded to silicone through TPU, and the main body formed by Kevlar and silicone is pressed into a protective shell semi-finished product with a back plate 11 and a frame 12. The silicone forms the inner surface of the protective shell semi-finished product, and the Kevlar forms the outer surface of the protective shell semi-finished product.

[0044] S3. The mold is then cooled to allow the protective shell semi-finished product to cool and solidify.

[0045] S4. The edge of the protective shell semi-finished product is rolled by a rolling machine to obtain a protective shell with rolled edge 13.

[0046] In step S2, the edge portion of the silicone rubber is bent along with the edge portion of the Kevlar to form a silicone rubber backplate, a silicone rubber frame, a Kevlar backplate, and a Kevlar frame; in step S4, the edge portion of the silicone rubber frame is bent along with the edge portion of the Kevlar to form a silicone rubber curl and a Kevlar curl.

[0047] The internal space of the Kevlar frame (excluding the silicone portion) prepared using this method is larger than that of a traditional Kevlar frame obtained by directly rolling the edges of Kevlar without silicone, especially in terms of the greater distance from the rolled edge to the back plate. This is mainly because during the rolling process, the silicone acts as the inner side of the protective shell, and the thickness of the silicone itself alters the bending position of the Kevlar, causing the bending position to be further away from the back plate by a certain distance.

[0048] When removing the protective case from the phone, the greater distance between the Kevlar rolled edge and the Kevlar backplate reduces the degree of Kevlar deformation required. As the Kevlar rolled edge expands outward, the silicone rolled edge tilts accordingly, allowing the phone to gain more space by squeezing the silicone rolled edge, thus making the phone easier to remove.

[0049] It's worth noting that although the bending position changes, the silicone rubber acts as the inside of the protective case. When the case is installed on the phone, the silicone rubber fills the increased space. Specifically, the silicone rubber fills the gap between the phone and the Kevlar back panel, the silicone rubber fills the gap between the phone and the Kevlar frame, and the silicone rubber fills the gap between the phone and the Kevlar rolled edge. This prevents the gap between the case and the phone from widening excessively, thus making it less likely for the phone to become loose inside the case.

[0050] After the phone is placed inside the protective case, the silicone rolled edge is preferably in a compressed state. More preferably, its compression degree is less than 1 / 2 of the maximum compressible degree. That is, the distance T from the Kevlar rolled edge to the Kevlar back plate is less than (the applied phone thickness H + the silicone back plate thickness L1 + the silicone rolled edge thickness L2). Typically, the silicone back plate thickness L1 = the silicone rolled edge thickness L2.

[0051] The Kevlar sheet has thermoplastic adhesive, and in step S2, the Kevlar sheet can be bonded to TPU, which also has thermoplastic properties, and has a good bonding effect after cooling and molding.

[0052] Thermoplastic adhesives can be made of thermoplastic resins, such as thermoplastic epoxy resins.

[0053] Preferably, the thickness of the Kevlar is 0.5mm-0.7mm, the thickness of the silicone is 0.2mm-0.4mm, and the thickness of the TPU is 0.02mm-0.03mm; during hot pressing, the heating temperature is 130℃-150℃, the heating time is 45s-55s, and the pressure of the molding die is 1.3 tons-1.5 tons.

[0054] More preferably, the thickness of the Kevlar is 0.6 mm, the thickness of the silicone is 0.3 mm, the thickness of the TPU is 0.025 mm, and during hot pressing, the heating temperature is 150°C, the heating time is 50 s, and the pressure of the molding die is 1.4 tons.

[0055] In this embodiment of the invention, in step S3, the molding die is cooled and formed without opening the mold after hot pressing by its cooling system.

[0056] Preferably, during cooling molding, the molding die is kept under pressure and cooled.

[0057] Please refer to the details. Figure 3 The forming mold includes a punch 101, a die 102, a heating system, and a cooling system.

[0058] The cooling system has multiple coolant channels 103 formed on the punch and / or die, and the cooling system continuously supplies coolant to the coolant channels 103 when cooling the punch and / or die of the forming mold.

[0059] The heating system has multiple hot liquid pipes 104 formed on the punch and / or die, and when the punch and / or die of the forming mold is heated, the heating system continuously supplies hot liquid to the hot liquid pipes 104.

[0060] After hot pressing, cooling can be carried out directly inside the molding die without the need for mold opening, resulting in faster production efficiency.

[0061] Preferably, at least the punch or at least the die is capable of being driven to open and close by a drive mechanism, such as a hydraulic lifting mechanism, which can provide the required closing pressure.

[0062] The mold cavity after the punch and die are closed corresponds to the back plate and frame of the protective shell (including the part before the edge is rolled).

[0063] After hot pressing, cooling can be carried out directly inside the molding die without the need for mold opening, resulting in faster production efficiency.

[0064] The structure of the edge-rolling part of the edge-rolling machine used in this preparation method can be found in [reference needed]. Figure 4 .

[0065] Using the thickness of the phone as the vertical axis, the width of the phone as the horizontal axis, and the length of the phone as the vertical axis:

[0066] The rolled edge structure includes a positioning seat with a positioning groove for vertically accommodating a portion of the protective shell, and exposes the portion of the edge away from the back panel.

[0067] The rolled edge structure also includes a first rolled edge plate for longitudinally pressing the frame of the protective shell, a second rolled edge plate for laterally pressing the frame of the protective shell, a drive assembly for driving the first and second rolled edge plates, and a heating assembly for heating the first and second rolled edge plates. The first rolled edge plate has two opposing pieces, and the second rolled edge plate has two opposing pieces.

[0068] The driving assembly is used to drive the first edge-rolling plate and the second edge-rolling plate toward the protective shell near the positioning groove to roll the edge of the protective shell. The driving assembly is also used to drive the first edge-rolling plate and the second edge-rolling plate away from the protective shell on the positioning groove to facilitate the picking and placing of the protective shell.

[0069] The drive assembly may include four motor lead screw assemblies, each corresponding to a rolled edge plate.

[0070] The heating element may include an electric heating element mounted on a corresponding rolled edge plate.

[0071] The rolled edge structure also includes a clamping assembly for pressing the protective shell. When the protective shell is vertically positioned on the positioning groove 202, its opening faces upward. The clamping block 205 of the clamping assembly, driven by the lifting component of the clamping assembly, presses down on the inner side of the back plate 11 of the protective shell, making the protective shell less prone to displacement.

[0072] The clamping block 205 can simulate the shape of a mobile phone. When curling the edge, the position of the silicone and the clamping block restricts the bending position of the edge on the frame, causing it to move upward and change accordingly.

[0073] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A method of manufacturing a Kevlar protective shell with a shock absorbing structure, characterized in that, The preparation method comprises S1, placing the cut Kevlar sheet and the organic silicone glue in a forming mold, wherein one side of the organic silicone glue has a layer of TPU, and the side of the organic silicone glue with the TPU is attached to the Kevlar; S2, the forming mold is first subjected to hot press forming, so that the Kevlar is bonded to the organic silicone glue through the TPU, and the main body formed by the Kevlar and the organic silicone glue is pressed into a protective shell semi-finished product with a back plate and a frame, the organic silicone glue forms an inner side surface of the protective shell semi-finished product, and the Kevlar forms an outer side surface of the protective shell semi-finished product; S3, the forming mold is then cooled to cool and form the protective shell semi-finished product; S4, the frame of the protective shell semi-finished product is crimped by a crimping machine to obtain the protective shell; wherein the crimping machine comprises a pressing assembly for pressing the protective shell, and the pressing block of the pressing assembly simulates the shape of a mobile phone; during crimping, the bending position corresponding to crimping on the frame is changed by the position limitation of the organic silicone glue and the pressing block.

2. The method for preparing a Kevlar protective shell with a shock-absorbing structure according to claim 1, characterized in that, In step S3, the forming mold is subjected to non-opening mold cooling and forming through its cooling system after hot pressing.

3. The method of claim 1 or 2, wherein the method further comprises the step of: The thickness of the Kevlar is 0.5-0.7 mm, the thickness of the organic silicone glue is 0.2-0.4 mm, and the thickness of the TPU is 0.02-0.03 mm.

4. The method for preparing a Kevlar protective shell with a shock-absorbing structure according to claim 3, characterized in that, During hot press forming, the heating temperature is 130-150°C, the heating time is 45-55 s, and the pressure of the forming mold is 1.3-1.5 tons.

5. The method for preparing a Kevlar protective shell with a shock-absorbing structure according to claim 4, characterized in that, The thickness of the Kevlar is 0.6 mm, the thickness of the organic silicone glue is 0.3 mm, and the thickness of the TPU is 0.025 mm. During hot press forming, the heating temperature is 150°, the heating time is 50 s, and the pressure of the forming mold is 1.4 tons.

6. The method of claim 1 or 2 or 4 or 5, wherein the method further comprises the step of: During cooling and forming, the forming mold is pressure-maintained and cooled.

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