Composite plate structure and manufacturing method thereof

Abstract

A composite plate structure includes a composite plate and a resin component. The composite plate includes a first fiber layer, a second fiber layer and a core layer. The second fiber layer has a first region, wherein an area of the second fiber layer is smaller than an area of the first fiber layer. The core layer is disposed between the first fiber layer and the second fiber layer, wherein the core layer is exposed at the first region. The resin component is connected to the composite plate, wherein the resin component is combined with the core layer at the first region. In addition, a manufacturing method of the composite plate is also provided.

What is claimed is: 
     
         1 . A composite plate structure, comprising:
 a composite plate, comprising:   a first fiber layer;   a second fiber layer, having a first region, wherein an area of the second fiber layer is smaller than an area of the first fiber layer; and   a core layer, disposed between the first fiber layer and the second fiber layer, wherein the core layer is exposed at the first region; and   a resin component, connected to the composite plate, wherein the resin component is combined with the core layer at the first region.   
     
     
         2 . The composite plate structure as recited in  claim 1 , wherein the composite plate has a sidewall, the core layer is exposed by the sidewall, and the resin component is connected to the sidewall. 
     
     
         3 . The composite plate structure as recited in  claim 1 , wherein the composite plate has a peripheral edge, the peripheral edge has a plurality of recessed portions, the resin component has a plurality of protruding portions, and the protruding portions are respectively fitted into the recessed portions. 
     
     
         4 . The composite plate structure as recited in  claim 3 , wherein the recessed portions are formed by a punching process. 
     
     
         5 . The composite plate structure as recited in  claim 3 , wherein an extending direction of each of the recessed portions has an inclination angle relative to the peripheral edge. 
     
     
         6 . The composite plate structure as recited in  claim 5 , wherein the inclination angle is between 10 to 170 degrees. 
     
     
         7 . The composite plate structure as recited in  claim 1 , wherein a portion of the second fiber layer is removed to expose the core layer at the first region, the first region divides the second fiber layer into a second region and a third region, and the core layer at the second region and the third region is covered by the second fiber layer. 
     
     
         8 . The composite plate structure as recited in  claim 7 , wherein an area of the second region is greater than an area of the third region. 
     
     
         9 . The composite plate structure as recited in  claim 7 , wherein the composite plate has a peripheral edge, and the third region is adjacent to the peripheral edge. 
     
     
         10 . The composite plate structure as recited in  claim 7 , wherein the portion of the second fiber layer is removed by a milling process, a laser perforation process, or a mechanical drilling process. 
     
     
         11 . The composite plate structure as recited in  claim 1 , wherein a material of the first fiber layer and the second fiber layer comprises carbon fibers, glass fibers, Kevlar fibers, synthetic fibers, or natural fibers. 
     
     
         12 . The composite plate structure as recited in  claim 1 , wherein a material of the first fiber layer and the second fiber layer comprises fiber yarn bundle mixed resin. 
     
     
         13 . The composite plate structure as recited in  claim 12 , wherein the resin is a thermoplastic resin or a thermosetting resin. 
     
     
         14 . The composite plate structure as recited in  claim 1 , wherein a material of the core layer comprises plastic, bamboo slices, carbon fibers, glass fibers, synthetic fibers, or natural fibers. 
     
     
         15 . The composite plate structure as recited in  claim 1 , wherein the second fiber layer is coplanar with the resin component located at the first region. 
     
     
         16 . A manufacturing method of a composite plate structure, comprising:
 providing a composite plate, wherein the composite plate comprises a first fiber layer, a second fiber layer and a core layer, and the core layer is disposed between the first fiber layer and the second fiber layer;   removing a portion of the second fiber layer, so as to enable the core layer to be exposed at a first region of the second fiber layer; and   providing a melted resin to the composite plate by an injection molding process, wherein a portion of the melted resin flows through the core layer exposed by the second fiber layer to a space between the first fiber layer and the second fiber layer, and the melted resin forms a resin component connected to the composite plate after being cured.   
     
     
         17 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein the composite plate has a sidewall, the core layer is exposed by the sidewall, and the step of forming the resin component comprises:
 connecting the resin component to the sidewall.   
     
     
         18 . The manufacturing method of the composite plate structure as recited in  claim 16 , comprising:
 forming a plurality of recessed portions at a peripheral edge of the composite plate, wherein the resin component has a plurality of protruding portions, and the protruding portions are respectively fitted into the recessed portions.   
     
     
         19 . The manufacturing method of the composite plate structure as recited in  claim 18 , wherein the step of forming the recessed portions comprises:
 forming the recessed portions by a punching process.   
     
     
         20 . The manufacturing method of the composite plate structure as recited in  claim 18 , wherein an extending direction of each of the recessed portions has an inclination angle relative to the peripheral edge. 
     
     
         21 . The manufacturing method of the composite plate structure as recited in  claim 20 , wherein the inclination angle is between 10 to 170 degrees. 
     
     
         22 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein the first region divides the second fiber layer into a second region and a third region, and the core layer at the second region and the third region is covered by the second fiber layer. 
     
     
         23 . The manufacturing method of the composite plate structure as recited in  claim 22 , wherein an area of the second region is greater than an area of the third region. 
     
     
         24 . The manufacturing method of the composite plate structure as recited in  claim 22 , wherein the composite plate has a peripheral edge, and the third region is adjacent to the peripheral edge. 
     
     
         25 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein the step of removing the portion of the second fiber layer comprising:
 removing the portion of the second fiber layer by a milling process, a laser perforation process, or a mechanical drilling process.   
     
     
         26 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein a material of the first fiber layer and the second fiber layer comprises carbon fibers, glass fibers, Kevlar fibers, synthetic fibers, or natural fibers. 
     
     
         27 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein a material of the first fiber layer and the second fiber layer comprises fiber yarn bundle mixed resin. 
     
     
         28 . The manufacturing method of the composite plate structure as recited in  claim 27 , wherein the resin is a thermoplastic resin or a thermosetting resin. 
     
     
         29 . The manufacturing method of the composite plate structure as recited in  claim 16 , wherein a material of the core layer comprises plastic, bamboo slices, carbon fibers, glass fibers, synthetic fibers, or natural fibers.