Composite component forming method

Abstract

A composite component forming method comprises a providing step, a setting step, a first forming step and a second forming step. The pre-formed substrate is formed into a predetermined shape by two different forming pressures. The forming pressure and the deformation amount of the pre-formed substrate are dispersed, so that the phenomenon that the formed substrate is broken due to the fact that the injection pressure of the high polymer material borne by the formed substrate in a single time is too large and the deformation amount of the substrate is large in the die casting forming process can be avoided, and the yield of formed products can be improved.

Description

Technical Field

[0001] The invention relates to a forming method, in particular to a composite component forming method. Background Art

[0002] Conventional methods of forming composite components with predetermined shapes, for example, refer to Figure 1 The metal-polymer composite component 1 is formed by a metal plate 11 with a predetermined shape and a glue layer 12 composed of a polymer covering the surface of the metal plate 11, and the side of the metal plate 11 has a side end arc structure 111; the metal plate 11 and the glue layer 12 are usually combined by the following method: Figure 1 The molding method shown is completed by using a molding mold; the molding mold has a lower mold 100A and an upper mold 100B, the upper mold 100B has an injection hole, and the side surface of the lower mold 100A adjacent to the bottom has a concave secondary molding area 101. The forming method of the metal-polymer composite component 1 is briefly described as follows: a flat sheet of metal plate 10 is placed in the opening of the lower mold 100A, and then the upper mold 100B and the lower mold 100A are molded and pressed to form a preformed substrate 10A having the same contour as the lower mold 100A in the metal plate 10; then, a polymer material 102 is injected from the injection hole into the surface of the preformed substrate 10A located in the lower mold 100A, and the pressure of the polymer material 102 injected into the forming mold is used to push the preformed substrate 10A, so that the preformed substrate 10A is deformed at a position corresponding to the secondary forming area 101, and forms a shape corresponding to the secondary forming area 101 to form the side end arc structure 111, thereby obtaining the metal-polymer composite component semi-finished product 1A; finally, the metal-polymer composite component semi-finished product 1A is surface treated by post-processing (such as CNC, anodizing, painting, electroplating, etc.) to obtain a surface having the following characteristics: Figure 1 The metal-polymer composite component 1 shown has a side arc-shaped structure 111.

[0003] However, the formation of the side arc structure 111 of the aforementioned metal-polymer composite component 1 is completely provided by the injection pressure of the polymer material 102. Therefore, the preformed substrate 10A is squeezed and expanded by the polymer material 102 at one time, and it is easy to break due to excessive deformation. Summary of the invention

[0004] The object of the present invention is to provide a composite component forming method which can disperse the forming pressure to improve the yield of the formed product.

[0005] The composite component forming method of the present invention comprises: a providing step, a setting step, a first forming step, and a second forming step.

[0006] The providing step includes preparing a molding mold and a pre-molded substrate, the molding mold having a lower mold and an upper mold that can be matched with each other, the lower mold having a side wall surface and a bottom surface connected to the side wall surface, and a receiving space that can accommodate the pre-molded substrate is defined by the side wall surface and the bottom surface, and the side wall surface has a molding portion adjacent to the bottom surface and recessed inward, the upper mold has a molding hole connected to the receiving space, the pre-molded substrate is sheet-shaped, has a molding side wall whose length is not less than the side wall surface and is parallel to the side wall surface, and a molding bottom connected to the molding side wall and parallel to the bottom surface of the lower mold.

[0007] The setting step includes placing the preformed substrate into the accommodating space, and performing a first mold closing of the upper mold and the lower mold so that there is a gap between the opposing surfaces of the upper mold and the lower mold and they do not contact each other, thereby forming a molding space between the surface of the preformed substrate and the upper mold, and generating a forming space between the forming side wall of the preformed substrate and the forming portion of the lower mold.

[0008] The first forming step includes injecting polymer material from the molding hole into the molding space, and using the injection pressure of the polymer material to push the preformed substrate, so that the forming side wall of the preformed substrate is pushed and deformed toward the forming space to generate a first deformation portion.

[0009] The second forming step includes, after the first forming step, performing a second mold closing step, so that the surfaces of the upper mold and the lower mold relative to each other are in close contact, and using the mold closing pressure to extrude the polymer material to further push the first deformation part, so that the first deformation part is further deformed into the second deformation part, so that the pre-formed substrate is formed into a formed substrate, and at the same time, a polymer layer covering the surface of the formed substrate is formed to obtain a semi-finished product.

[0010] Preferably, in the composite component forming method of the present invention, the side wall surface of the lower mold further has an upper side wall surface portion, and the forming portion is between the upper side wall surface portion and the bottom surface.

[0011] Preferably, the composite component forming method of the present invention further comprises a processing step of taking the semi-finished product out of the forming mold and removing the upper portion of the second deformation portion of the forming substrate of the semi-finished product.

[0012] Preferably, in the composite component forming method described in the present invention, the upper mold has a mold cover that can cover the lower mold and an extension portion extending from the mold cover to the accommodating space. In the setting step, when the upper mold and the lower mold are closed for the first time, the extension portion will extend to the accommodating space.

[0013] Preferably, in the composite component forming method described in the present invention, the mold casting hole is located corresponding to the extension portion, the polymer layer of the semi-finished product has a base glue portion covering the surface of the pre-formed substrate, and an extension glue portion extending from the surface of the base glue portion and corresponding to the shape and position of the mold casting hole, and the processing step also removes the extension glue portion.

[0014] Preferably, in the composite component forming method described in the present invention, the upper mold further comprises an annular groove surrounding the extension portion and allowing the forming side wall of the preformed substrate to extend into.

[0015] Preferably, in the composite component forming method described in the present invention, the length of the forming side wall of the preformed substrate is greater than the length of the side wall surface of the lower mold, and has a height protruding from the lower mold, and the depth of the annular groove is not less than the height.

[0016] Preferably, in the composite component forming method described in the present invention, the extension portion has a parallel section parallel to the upper side wall surface of the lower mold and an inwardly retracted section gradually extending inwardly from the parallel section. When the upper mold and the lower mold are closed for the first time, the forming side wall of the preformed substrate and the corresponding position of the parallel section and the upper side wall surface will be in close contact with each other.

[0017] Preferably, in the composite component forming method of the present invention, when the upper mold and the lower mold are closed for the first time, the position of the retracted section of the upper mold corresponds to the forming portion of the lower mold.

[0018] Preferably, in the composite component forming method described in the present invention, the surface of the preformed substrate also has a microstructure, and the setting step includes placing the preformed substrate into the accommodating space with the microstructure facing the upper mold.

[0019] The beneficial effect of the present invention is that the preformed substrate is formed into a predetermined shape by using two different forming pressures. Since the forming pressure and deformation of the preformed substrate are dispersed, the forming substrate can be prevented from being broken during the molding process due to excessive high polymer material injection pressure and large deformation of the substrate in a single injection molding process, thereby improving the yield rate of the molded product. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a schematic flow diagram illustrating a method for forming a composite component in the background art;

[0021] Figure 2 is a schematic flow chart illustrating this embodiment of the composite component forming method of the present invention; and

[0022] Figure 3 It is a text flow chart that illustrates the implementation steps of this embodiment of the present invention. DETAILED DESCRIPTION

[0023] The present invention is described in detail below with reference to the accompanying drawings and embodiments.

[0024] It should be noted that the drawings of the present invention are only intended to illustrate the structures and / or relative positions of components and are not related to the actual sizes of the components.

[0025] An embodiment of the composite component forming method is described below.

[0026] Related References Figure 2 , Figure 3 This embodiment of the composite component forming method of the present invention includes a providing step 21, a setting step 22, a first forming step 23, a second forming step 24, and a processing step 25.

[0027] First, the providing step 21 is performed to prepare a molding die 300 and a preformed substrate 200 .

[0028] The molding die 300 comprises a lower die 3 and an upper die 4 which can be matched with each other.

[0029] Specifically, the lower mold 3 has a side wall 31 and a bottom surface 32 connected to the side wall 31, and the side wall 31 and the bottom surface 32 together define a receiving space 33 for accommodating the preformed substrate 200, and the side wall 31 has an upper side wall surface 311 and a forming portion 312 between the upper side wall surface 311 and the bottom surface 32 and recessed inward.

[0030] The upper mold 4 has a mold cover 41 that can cover the lower mold 3, an extension portion 42 extending from the mold cover 41 to the accommodating space 33, a mold casting hole 43 that passes through two opposite surfaces of the extension portion 42 and can communicate with the outside, and an annular groove 44 that surrounds the extension portion 42 and has a width not less than the thickness of the preformed substrate 200. The extension portion 42 has a parallel section 421 that is parallel to the upper side wall surface 311 of the lower mold 3 and a retracted section 422 that gradually retracts and extends from the parallel section 421.

[0031] The preformed substrate 200 can be made of materials such as metals and alloys, and is obtained by preforming a flat substrate (not shown) (e.g., preforming by stamping) to have substantially the same appearance size as the surface of the accommodating space 33 of the lower mold 3. Specifically, the preformed substrate 200 has a forming side wall 201 whose length is not less than the side wall surface 31 of the lower mold 3 and is parallel to the side wall surface 31, and a forming bottom 202 connected to the forming side wall 201 and parallel to the bottom surface 32 of the lower mold 3.

[0032] In this embodiment, the preformed substrate 200 has a flat surface and the length of the forming side wall 201 is greater than the side wall surface 31 of the lower mold 3. Therefore, when the preformed substrate 200 is placed on the lower mold 3, the forming side wall 201 will protrude from the side wall surface 31 of the lower mold 3. The annular groove 44 of the upper mold 4 can be used to accommodate the forming side wall 201, and the depth of the annular groove 44 is not less than the height of the forming side wall 201 protruding from the lower mold 3.

[0033] In some embodiments, the surface of the preformed substrate 200 facing the upper mold 4 may also have a microstructure (not shown). The microstructure may be used to enhance the adhesion with the subsequently formed polymer layer 92 to increase the bonding strength.

[0034] Next, the setting step 22 is performed to place the preformed substrate 200 into the accommodating space 33 of the lower mold 3 to perform the first mold closing of the lower mold 3 and the upper mold 4, so that there is a gap G between the opposite surfaces of the lower mold 3 and the upper mold 4 and they do not contact each other, so that there is a gap between the surface of the preformed substrate 200 and the upper mold 4 to form a molding space M1, and a forming space M2 is generated between the forming side wall 201 of the preformed substrate 200 and the forming portion 312 of the lower mold 3.

[0035] In detail, when the upper mold 4 and the lower mold 3 are molded together, the extension portion 42 of the upper mold 4 will extend to the accommodating space 33, and the parallel section 421 of the extension portion 42 and the upper side wall surface portion 311 of the lower mold 3 will abut against each other to clamp the preformed substrate 200, so that the upper mold 4 and the lower mold 3 and the preformed substrate 200 define the molding space M1 and the forming space M2 respectively. In addition, because the length of the forming side wall 201 of the preformed substrate 200 is greater than the side wall surface 31, the forming side wall 201 will protrude from the lower mold 3 and extend into the annular groove 44 of the upper mold 4 accordingly.

[0036] Then, the first forming step 23 is performed, in which the polymer material 102 is injected into the molding space M1 from the molding hole 43, and the injection pressure of the polymer material 102 is used to push the pre-formed substrate 200, so that the forming side wall 201 of the pre-formed substrate 200 is pushed and deformed toward the forming space M2, so that a first deformation portion 201A is generated at the position of the forming side wall 201 corresponding to the forming space M2.

[0037] It should be noted that the polymer material 102 can be a thermoplastic resin or a thermosetting resin, and the first forming step 23 is to inject the heated molten polymer material 102 into the mold hole 43 under pressure. The pressure of injecting the polymer material 102 into the lower mold 3 may vary depending on the viscosity of the molten polymer material 102, the material type of the preformed substrate 200, the predetermined deformation amount, and / or the time required for the polymer material 102 to fill the mold space M1. In some embodiments, the polymer material 102 is selected from a resin with a melting point between 150 and 300° C., and the polymer material 102 is injected into the molding mold 300 at a pressure of about 100 to 200 MPa, and the pressurization time is about 10 to 60 seconds to deform the preformed substrate 200. In addition, the molding mold 300 can also be heated simultaneously during the process of injecting the polymer material 102.

[0038] Next, the second forming step 24 is performed, and a second mold closing is performed after the first forming step 23 to close the molding hole 43 and bring the relative surfaces of the upper mold 4 and the lower mold 3 into contact and close contact to eliminate the gap G, and the polymer material 102 is pushed again by the mold closing pressure to further push the first deformation portion 201A, so that the first deformation portion 201A is further compressed and deformed into a second deformation portion 201B having a shape corresponding to the molding portion 312, so that the pre-formed substrate 200 forms a formed substrate 91, and at the same time forms a polymer layer 92 covering the surface of the formed substrate 91, so as to obtain a semi-finished product 900, and the polymer layer 92 has a bottom glue portion 921, and an extended glue portion 922 extending from the bottom glue portion 921 and corresponding to the shape and position of the molding hole 43.

[0039] Finally, the processing step 25 is performed to remove the semi-finished product 900 from the molding die 300, and the upper portion of the second deformation portion 201B of the molding substrate 91 and the extended adhesive portion 922 are removed to obtain the semi-finished product 900. Figure 1 The metal-polymer composite structure 1 is shown.

[0040] The present invention uses a secondary molding method to provide the preformed substrate 200 with molding pressure during the molding process, thereby dispersing the molding pressure and reducing the single deformation of the preformed substrate 200, thereby avoiding the prior art that uses a single injection pressure to cause the substrate (such as Figure 1 The deformation of the metal plate 10) shown in the figure can effectively improve the forming yield of the composite component, thereby achieving the purpose of the present invention.

Claims

1. A composite component forming method, characterized in that: Include: The steps of preparing a molding die and a preformed substrate are provided. The molding die has a lower die and an upper die that can be matched with each other, the lower die has a side wall surface and a bottom surface connected to the side wall surface, and the side wall surface and the bottom surface jointly define a receiving space for receiving the preformed substrate, and the side wall surface has a molding portion adjacent to the bottom surface and recessed inward, the upper die has a molding hole connected to the receiving space, the preformed substrate is sheet-shaped, has a molding side wall whose length is not less than that of the side wall surface and is parallel to the side wall surface, and a molding bottom connected to the molding side wall and parallel to the bottom surface of the lower die; a setting step of placing the preformed substrate into the accommodating space, and performing a first mold closing of the upper mold and the lower mold, so that a gap exists between the surfaces of the upper mold and the lower mold facing each other and the surfaces do not contact each other, thereby forming a molding space between the surface of the preformed substrate and the upper mold, and generating a forming space between the forming side wall of the preformed substrate and the forming portion of the lower mold; The first forming step is to inject a polymer material into the molding space from the molding hole, and use the injection pressure of the polymer material to push the preformed substrate, so that the forming side wall of the preformed substrate is pushed and deformed toward the molding space to generate a first deformation portion; and The second forming step is to perform a second mold closing after the first forming step, so that the surfaces of the upper mold and the lower mold relative to each other are in close contact, and the mold closing pressure is used to extrude the polymer material to further push the first deformation part, so that the first deformation part is further deformed into the second deformation part, so that the pre-formed substrate is formed into a formed substrate, and at the same time, a polymer layer covering the surface of the formed substrate is formed to obtain a semi-finished product.

2. The composite component forming method according to claim 1, characterized in that: The side wall surface of the lower mold also has an upper side wall surface, and the molding portion is between the upper side wall surface and the bottom surface.

3. The composite component forming method according to claim 2, characterized in that: The method also includes a processing step of taking the semi-finished product out of the forming mold and removing the upper part of the second deformation part of the forming substrate of the semi-finished product.

4. The composite component forming method according to claim 3, characterized in that: The upper mold has a mold cover that can cover the lower mold and an extension portion extending from the mold cover to the accommodating space. In the setting step, when the upper mold and the lower mold are molded for the first time, the extension portion will extend to the accommodating space.

5. The composite component forming method according to claim 4, characterized in that: The molded hole is located corresponding to the extension part. The polymer layer of the semi-finished product has a base glue part covering the surface of the preformed substrate, and an extension glue part extending from the surface of the base glue part and corresponding to the shape and position of the molded hole. The processing step also removes the extension glue part.

6. The composite component forming method according to claim 1, characterized in that: The upper mold also has an annular groove surrounding the extension portion and allowing the forming side wall of the preformed substrate to extend into.

7. The composite component forming method according to claim 6, characterized in that: The length of the forming side wall of the preformed substrate is greater than the length of the side wall surface of the lower mold, and has a height protruding from the lower mold, and the depth of the annular groove is not less than the height.

8. The composite component forming method according to claim 4, characterized in that: The extension portion has a parallel section parallel to the upper side wall surface of the lower mold and a retracted section gradually retracting and extending inward from the parallel section. When the upper mold and the lower mold are molded for the first time, the forming side wall of the preformed substrate and the corresponding position of the parallel section and the upper side wall surface will be in close contact with each other.

9. The composite component forming method according to claim 8, characterized in that: When the upper die and the lower die are closed for the first time, the position of the retracted section of the upper die corresponds to the forming portion of the lower die.

10. The composite component forming method according to claim 1, characterized in that: The surface of the preformed substrate also has a microstructure, and the arrangement step is to place the preformed substrate into the accommodating space with the microstructure facing the upper mold.

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