A plate manufacturing process for high-speed surface vehicle

Abstract

The present invention discloses a board manufacturing process for a high-speed surface vehicle, comprising the following steps: designing a molding die according to the outer contour of the board skin; designing the ply angle of the carbon fiber prepreg, laminating the carbon fiber prepreg together on the molding die to form a prepreg preform, and then curing and forming the skin; taking out the cured skin to prepare a skin shell of the board, the interior of the skin shell is a cavity, and the cavity of the skin shell is filled with foam to prepare the board. The board manufacturing process for a high-speed surface vehicle provided by the present invention is composed of an external carbon fiber composite material and an internal foam core material. Compared with the surfboard produced by the traditional process, it has the advantages of light weight, good rigidity, anti-collision energy absorption and high safety, and solves the problem that the board manufacturing process in the prior art cannot have rigidity, anti-collision energy absorption and safety.

Description

Technical Field

[0001] The invention relates to the technical field of high-speed surface vehicles, and in particular to a board manufacturing process for a high-speed surface vehicle. Background Art

[0002] Most of the current surface vehicles are driven by waves, and the gliding speed of the board on the water is not high. However, for high-speed manned surface vehicles, it not only pursues high speed, but also needs to consider the load, which is generally the weight of a single person, that is, within 100kg.

[0003] The board is an important component of high-speed surface vehicles. Due to the manned nature of the board, its manufacturing process and quality requirements are extremely strict in order to ensure the safety of the user. In the early days, pure foam materials were usually used, but the strength of foam materials (EVA, polystyrene, polyester) is relatively low, usually around a few MPa, and the material stiffness modulus is below 1 GPa, which cannot meet the needs of high-speed manned navigation.

[0004] Patent 2015103069126 proposes a method for preparing an improved unsaturated polyester-based composite material, which has the characteristics of light weight and has certain improvements in aging resistance and creep resistance, but still has deficiencies in stiffness and anti-collision energy absorption. Patent 2019109581065 proposes an environmentally friendly inflatable surfboard composite material and its preparation method, which has certain improvements in board ladder strength, but based on user safety considerations, its strength poses certain risks when sailing at high speeds. Patent 2020106136833 proposes a high-strength surfboard using a modified composite board, which improves the board strength by adding a certain amount of graphene, but the design is deficient in anti-collision energy absorption when sailing at high speeds.

[0005] Therefore, it is necessary to develop a panel manufacturing process that combines rigidity, anti-collision energy absorption and safety. Summary of the invention

[0006] The present invention provides a plate body manufacturing process for a high-speed surface vehicle, so as to solve the problem that the plate body manufacturing process in the prior art cannot have both rigidity, anti-collision energy absorption and safety.

[0007] The present invention provides a board manufacturing process for a high-speed surface vehicle, the board manufacturing process comprising the following steps:

[0008] Design the forming mold according to the outer contour of the panel skin;

[0009] Design the ply angle of carbon fiber prepreg, laminate the carbon fiber prepreg together on the molding die to make a prepreg preform, and then solidify it into a skin;

[0010] The cured and formed skin is taken out to prepare a skin shell of the panel body, the interior of the skin shell is a cavity, and the cavity of the skin shell is filled with foam to prepare a panel body.

[0011] Furthermore, the board manufacturing process also includes a molding die design process:

[0012] The panel skin is projected in the horizontal direction, and the panel skin is divided into an upper skin and a lower skin with the maximum projection contour line as the parting line. According to the outer contours of the upper skin and the lower skin, forming molds corresponding to the upper skin and the lower skin are designed respectively.

[0013] Furthermore, the board manufacturing process also includes a design process for the carbon fiber prepreg ply angle:

[0014] The length direction of the plate is used as the 0-degree reference direction for the ply, and the width direction of the plate is used as the 90-degree reference direction for the ply. During the ply laying process, the proportion of carbon fibers in the 0-degree direction is controlled at 40%-50% to increase the bending stiffness in the length direction of the plate; the proportion of carbon fibers in the 90-degree direction is controlled at 10-20% to increase the stiffness in the lateral direction of the plate; the remaining carbon fibers are distributed in the 45-degree and -45-degree directions to increase the torsional stiffness of the plate.

[0015] Furthermore, according to the design process of the carbon fiber prepreg ply angle, the carbon fiber prepregs are laminated together in order, and the first-order non-rigid frequency of the obtained plate is above 80.0 Hz, and the vibration mode of the first-order mode is a bending mode.

[0016] Furthermore, after the carbon fiber prepreg ply angle is designed, the carbon fiber prepreg corresponding to the battery compartment position of the board is divided into sheets at different positions according to the battery compartment structure. Notches are provided on the sheets to ensure the draping of the carbon fiber prepreg at the battery compartment position on the molding mold. The notch cutting positions of the sheets at different positions are staggered and overlap by 10-20mm.

[0017] Furthermore, during the curing process, the air inside the prepreg preform formed by paving the carbon fiber prepreg is exhausted so that the internal pores of the prepreg preform are closed under the action of high temperature and high pressure, and the curing reaction occurs to improve the internal density of the cured skin.

[0018] Furthermore, the air inside the prepreg preform can be exhausted by a vacuum-assisted autoclave molding process, wherein the vacuum-assisted autoclave molding process comprises:

[0019] On the prepreg preform, PTFE cloth, perforated PE film and breathable felt are laid in sequence;

[0020] Install a vacuum nozzle on the vacuum bag, adhere the vacuum bag to the surface of the molding mold, complete the vacuum bag packaging of the prepreg preform, and verify the airtightness of the vacuum bag;

[0021] The forming mold with the PTFE cloth, the perforated PE film and the breathable felt is installed in the autoclave;

[0022] Connect the vacuum system in the autoclave to the vacuum nozzle of the vacuum bag, close the autoclave door, monitor the vacuum degree in the vacuum bag, and exhaust the air inside the preform by vacuum adsorption.

[0023] Furthermore, taking out the solidified skin, including the independent upper skin and lower skin, also includes the following operations: removing auxiliary materials in the process, removing process edges, applying a protective film to the surface where the skin and the forming mold are bonded for protection, performing interface bonding on the upper skin and the lower skin respectively, and after the interface bonding, performing butt bonding on the upper skin and the lower skin to obtain the skin shell of the panel body.

[0024] Furthermore, the board manufacturing process also includes a method of filling with foam:

[0025] Inject liquid polyurethane foam material into the cavity of the skin shell, then seal the injection hole, place the skin shell in a constant temperature room of 30℃-55℃, and wait for the polyurethane foam material to expand and solidify.

[0026] Furthermore, the board manufacturing process also includes a method for processing the forming mold:

[0027] Before production, the molding mold is surface treated to remove foreign matter on the surface and inspect the surface quality of the molding mold. If the surface quality of the molding mold is normal, apply liquid release agent on the surface of the molding mold, let it stand for 10-30 minutes, wait for the release agent to dry, and then apply 1-2 coats of release agent. The treatment is completed and ready for use.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] 1. The board body manufacturing process of the high-speed surface vehicle provided by the present invention comprises an outer carbon fiber composite material and an inner foam core material. Compared with the surfboard produced by the traditional process, the board body has the advantages of light weight, good rigidity, anti-collision energy absorption and high safety.

[0030] 2. In the board manufacturing process provided by the present invention, the ply angle design is performed before the carbon fiber prepreg is laid, and then the ply is laminated together. The ply angle design can improve the bending stiffness in the length direction of the board, and enhance the stiffness in the width direction and the torsional stiffness. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the implementation methods of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the implementation methods or the description of the prior art. Obviously, the drawings in the following description are only exemplary, and for ordinary technicians in this field, other implementation drawings can be derived from the provided drawings without creative work.

[0032] Figure 1 This is a process flow chart of the board manufacturing process in the embodiment of the present invention;

[0033] Figure 2 Schematic diagram of the parting line of the upper skin and the lower skin in an embodiment of the present invention;

[0034] Figure 3 It is a schematic diagram of a plate body with a first-order natural frequency greater than 80 Hz according to a designed ply angle in an embodiment of the present invention;

[0035] Figure 4 Schematic diagram of cutting and slicing of the upper skin prepreg in an embodiment of the present invention;

[0036] Figure 5 It is a schematic diagram of the overlap of the 1# sheet with the 2#, 3#, and 4# sheets in the sheet overlap and cut processing at the position of the upper skin battery compartment in an embodiment of the present invention;

[0037] Figure 6 It is a schematic diagram of the overlap of the 2# sheet and the 3# sheet in the sheet overlap and cut processing at the position of the upper skin battery compartment in an embodiment of the present invention;

[0038] Figure 7 It is a schematic diagram of the overlap of the 2# sheet and the 4# sheet in the sheet overlap and cut processing at the position of the upper skin battery compartment in an embodiment of the present invention;

[0039] Figure 8 It is the DMA curve of a typical resin matrix;

[0040] Fig. 9 It is the temperature-time curve and pressure-time curve in the process curve;

[0041] Fig.10 Schematic diagram of gluing the upper skin in an embodiment of the present invention;

[0042] Fig.11 Schematic diagram of the bonding of the lower skin in an embodiment of the present invention

[0043] Fig.12 It is a structural diagram of the hollow skin of the plate body in an embodiment of the present invention;

[0044] Fig.13 This is a structural diagram of a plate body filled with foam in an embodiment of the present invention;

[0045] Fig.14 This is a schematic diagram of foaming after the upper and lower skins are glued together in an embodiment of the present invention;

[0046] Numbers in the figure:

[0047] 1-upper skin, 2-lower skin, 3-parting line, 4-1# sheet, 5-2# sheet, 6-2# sheet, 7-4# sheet, 8-process flange, 9-cavity, 10-foam, 11-glue injection hole. DETAILED DESCRIPTION

[0048] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0049] like Figure 1 As shown, a plate manufacturing process for a high-speed surface vehicle includes the following steps:

[0050] Design the forming mold according to the outer contour of the panel skin;

[0051] Design the ply angle of carbon fiber prepreg, laminate the carbon fiber prepreg together on the molding die to make a prepreg preform, and then solidify it into a skin;

[0052] The cured and formed skin is taken out to prepare a skin shell of the panel body, the interior of the skin shell is a cavity, and the cavity of the skin shell is filled with foam to prepare a panel body.

[0053] According to the board manufacturing process of the high-speed surface vehicle provided by the present invention, the prepared board is composed of an external carbon fiber composite material and an internal foam core material, and has the advantages of light weight, good rigidity, anti-collision energy absorption and high safety.

[0054] The specific implementation process of the above-mentioned production process is as follows:

[0055] 1) In the present invention, the design process of the forming mold is: projecting the panel skin in the horizontal direction, taking the maximum projection contour line as the parting line, and dividing the panel skin into an upper skin and a lower skin, such as Figure 2 As shown, according to the outer contours of the upper skin and the lower skin, the forming molds corresponding to the upper skin and the lower skin are designed, wherein the mold surface corresponds to the outer surface of the product.

[0056] 2) Before production, the molding mold needs to be surface treated. The treatment method of the molding mold is as follows: surface treat the molding mold, remove foreign matter on the surface, clean the mold surface with alcohol (or ethyl acetate), inspect the surface quality of the molding mold, and if the surface quality of the molding mold is normal, apply liquid release agent on the surface of the molding mold (the amount of release agent is based on the ability to form a film on the surface), let it stand for 10-30 minutes, wait for the release agent to dry, and then apply 1-2 coats of release agent. The surface treatment of the molding mold is completed and ready for use.

[0057] 3) According to the material selection requirements, a carbon fiber fabric prepreg of a certain specification is selected according to the size of the skin. The carbon fiber fabric in this embodiment is made from a single bundle of carbon fiber yarn through industrial textile processing. The type of the single bundle of carbon fiber can be T300 grade specification or T700 grade specification, and the fabric type can be plain fabric or twill fabric.

[0058] The resin type in the prepreg is epoxy resin, and the volume content of the fiber in the prepreg is between 40% and 60%. The carbon fiber fabric / epoxy prepreg (hereinafter referred to as prepreg) can be obtained by commissioning the prepreg manufacturer. The prepreg is obtained in the form of a roll of raw materials with a certain width (0.3m-1.0m) and a certain length (50m-200m), covered by two layers of isolation films, and tightened on a hollow barrel.

[0059] The storage of prepreg has temperature requirements and timeliness. It needs to be placed in a low-temperature storage room during storage. When it is taken out for use, it needs to be aged for 24 hours at room temperature before the sheet can be cut and the subsequent process operations can be carried out. Prepreg must be used within the specified validity period. If it exceeds the specified validity period, it needs to be discarded and cannot be used in production.

[0060] 4) According to the shape and size of the upper skin, the carbon fiber prepreg ply angle is designed, and the carbon fiber prepregs are layered together in order on the molding mold.

[0061] The design ply angle refers to the angle between the warp direction in the carbon fiber fabric and the reference direction specified on the board. The commonly used design ply angles are 0 degrees, 45 degrees, 90 degrees and 135 degrees. Since the board not only needs to bear the water surface impact load along the length direction, but also may bear the left and right swing impact load in the width direction. At the same time, as a moving part, its own fundamental modal frequency has an important relationship with the dynamic strength of the board and the comfort of the occupants.

[0062] Therefore, when designing the ply, it is necessary to distribute the fibers at different angles in a reasonable proportion. The design process of the carbon fiber prepreg ply angle in the present invention is: the length direction of the board body is used as the 0-degree reference direction of the ply, and the width direction of the board body is used as the 90-degree reference direction of the ply. When laying the ply, the proportion of carbon fibers in the 0-degree direction is controlled at 40%-50% to improve the bending stiffness in the length direction of the board body; the proportion of carbon fibers in the 90-degree direction is controlled at 10-20% to improve the stiffness in the transverse direction of the board body; the remaining carbon fibers are distributed to the 45-degree direction and the -45-degree direction to improve the torsional stiffness of the board body. The ply angle design process provided by the present invention can improve the bending stiffness in the length direction of the board body, and enhance the stiffness in the width direction and the torsional stiffness.

[0063] According to the design process of the carbon fiber prepreg ply angle, the carbon fiber prepregs are laminated together in order, and the first-order non-rigid frequency of the obtained board is above 80.0HZ, and the vibration mode of the first-order mode is the bending mode, such as Figure 3 shown.

[0064] The first-order natural frequency of the plate obtained by the present invention can reach above 80.0HZ. The first-order natural frequency is relatively high, so that when the prepared aircraft moves at high speed on the sea surface, the turbulence frequency of the waves can be staggered to avoid the occurrence of frequency resonance, thereby improving the movement stability of the plate. Moreover, the vibration type of the first-order mode is bending along the length direction, so that its dynamic characteristics are consistent with the wave loads received by the plate during movement, ensuring the performance balance of the plate.

[0065] 5) On the surface treated forming mold, the carbon fiber fabric prepreg is laid according to the layup defined in step 4), the prepreg layup of the upper skin is completed, and the prepreg preform of the upper skin is manufactured.

[0066] When laying layers on the mold, the upper skin with the battery compartment has a complex curved surface and cannot be developed where the shape changes dramatically. Therefore, after the carbon fiber prepreg laying angle is designed, the carbon fiber prepreg corresponding to the battery compartment position of the board, that is, the upper skin carbon fiber prepreg, is divided into sheets at different positions according to the battery compartment structure. Notches are provided on the sheets to ensure the laying of the carbon fiber prepreg at the battery compartment position on the molding mold. The notches of the sheets at different positions are staggered and overlapped by 10-20mm to ensure the overall stiffness and strength of the board. The prepreg cutting of the upper skin is cut as follows: Figure 4 As shown in the figure, the overlap of the sheet at the battery compartment position of the upper skin and the overlap of different sheets in the cut processing are as follows Figure 5-7 shown.

[0067] 6) For the prepreg preform formed by paving carbon fiber prepreg, the air inside it is exhausted so that the internal pores of the prepreg preform are closed under the action of high temperature and high pressure, and the curing reaction occurs to improve the internal density of the cured skin.

[0068] In one embodiment, the air inside the prepreg preform can be evacuated by a vacuum assisted autoclave process.

[0069] For example, on the upper skin prepreg preform, lay out Teflon cloth, perforated PE film, and breathable felt in sequence, cut the vacuum bag film material (usually PA material) of appropriate size according to the area of ​​the upper skin molding mold, and install the vacuum air nozzle at the appropriate position of the vacuum bag film material. For the upper skin prepreg preform, one vacuum air nozzle is enough. Use high-temperature resistant sealing strips to bond the vacuum bag to the surface of the upper skin autoclave mold to complete the autoclave vacuum bag packaging of the upper skin prepreg preform, and connect the vacuum system to verify the air tightness of the vacuum bag to ensure that the vacuum bag is reliable in air tightness.

[0070] 7) Repeat steps 4), 5), and 6) on the molding mold corresponding to the lower skin to complete the preparation of the prepreg preform of the lower skin and the packaging of the autoclave vacuum bag, and perform airtightness verification to ensure that the vacuum bag is reliable in airtightness.

[0071] 8) Depending on the available volume inside the autoclave and the number of sensors inside, place the upper skin molding mold and the lower skin molding mold into the autoclave together or in batches to carry out the vacuum-assisted autoclave molding process. Before installing the molding mold into the autoclave, first arrange the thermocouple for temperature measurement of the autoclave inside the vacuum bag of the molding mold and fix it. At the same time, connect the vacuum system in the autoclave to the vacuum air nozzle of the vacuum bag, close the autoclave door, record the temperature, pressure and process parameters of the vacuum system in the autoclave, monitor the vacuum degree in the vacuum bag, and keep it within the specified value range (usually the vacuum degree is below -0.95Bar), and exhaust the air inside the preform by vacuum adsorption.

[0072] 9) The autoclave molding process is a process in which the preform formed by paving carbon fiber fabric prepreg is assisted by vacuum adsorption to expel the air inside the preform. At the same time, the preform is subjected to high temperature and high pressure (pressure inside the autoclave is greater than 1.0 Bar, temperature is greater than 90°C) to close the pores in the preform and cause the epoxy resin to undergo a curing reaction. The process parameters of the autoclave include the curve of temperature and pressure changing with time, which is determined by the resin matrix used in the preform and can usually be determined by the dynamic mechanical properties curve (Dynamic Mechanical Analysis, referred to as DMA curve) of the resin matrix. The shape of the DMA curve is as follows: Figure 8As shown. The process parameter control curve of the autoclave can be referred to Fig. 9 implement.

[0073] After the vacuum-assisted autoclave molding process, the upper and lower skins can be guaranteed to have good density, the fiber and resin interface is tightly bonded, and the resin curing degree is ideal. The fiber volume content of the upper and lower skins prepared by the autoclave molding process can usually be above 55%. Compared with the liquid molding process, the upper and lower skins processed by the autoclave molding process have more ideal stiffness and strength.

[0074] In the autoclave molding process, the PTFE cloth and the perforated PE film play a role of physical isolation to prevent the cured parts from being separated from the vacuum bag. The vacuum bag can provide a sealed cavity for the prepreg preform, ensuring that the process pressure is applied to the preform as a whole through the vacuum bag. The breathable felt is placed between the vacuum bag and the prepreg preform to ensure that the process pressure is applied evenly.

[0075] 10) After completing the autoclave curing process, take out the cured skin from the vacuum bag, including the independent upper skin and lower skin, remove the auxiliary materials in the process, remove the process edges, and apply a protective film to the surface where the skin and the mold are bonded (the surface with appearance quality). The protective film is usually a silicone paper with a thickness of about 0.5 mm) for protection.

[0076] 11) The upper skin and the lower skin are respectively bonded with embedded parts through the interface bonding process.

[0077] The interface bonding process requires bonding tooling, which includes upper tooling, lower tooling, and interface positioning tooling. The carbon fiber upper skin and carbon fiber lower skin are fixed on the upper tooling and lower tooling respectively, and the interface bonding positioning tooling is used to position the interface parts to be bonded, and the interface parts in the panel body are bonded to the corresponding upper skin / lower skin in the form of bonding.

[0078] The positioning accuracy of the glued interface is ensured by the interface positioning tooling, and the positioning accuracy can be guaranteed to be within 0.1 mm. These reserved interfaces are encapsulated inside the board body by gluing, which not only ensures the connection strength, but also supports the plugging and installation of universal interfaces. Before bonding, the bonding surface of the interface parts and the corresponding bonding positions on the skin need to be lightly polished and cleaned. 100#-200# water sandpaper can be used for polishing, and commonly used surface cleaners (such as ethyl acetate, alcohol, deionized water, etc.) can be used for cleaning.

[0079] Apply a certain amount of structural adhesive on the bonding surface of the interface part. The composition of the structural adhesive can be acrylic, epoxy or polyurethane. The amount of structural adhesive is weighed using an electronic scale with a range of less than 2 kg and an accuracy of 0.01 gram. The total amount of glue used for the interface bonding on the entire board is generally less than 50 grams, so as to form a glue layer with a thickness of 0.2-1.0mm on the bonding surface. After the interface coated with adhesive is bonded to the skin, it is fixed with an interface positioning tool and left to stand for more than 30 minutes. The schematic diagram of the bonding structure of the upper skin is shown in Fig.10 As shown in the figure, the position of the adhesive joints in the lower skin and the effect after adhesive bonding are as follows Fig.11 shown.

[0080] 12) After the adhesive is cured, the upper and lower skins are bonded together. This bonding process is also completed on the bonding tooling of the plate. Clean and lightly polish the surface along the process flange of the upper / lower skin, and dry it after the flange surface is treated for later use. For more information about process flanges, please refer to Fig.10 and Fig.11 shown.

[0081] Apply the same structural adhesive used in step 11) to the process flanges of the upper and lower skins. The amount of adhesive used should be sufficient to form a certain thickness (0.2mm-1.0mm) of adhesive layer at the flanges. The structural adhesive can be applied only on one side of the flange to be glued, for example, only on the flange of the lower skin. Turn the upper tooling over so that the flanges of the upper / lower skin are relative to each other, so that the upper tooling and the lower tooling are docked along the positioning holes, and the upper and lower tooling are pressed and locked by the force-applying device on the tooling to achieve the tight fit of the upper and lower skins at the process flanges, and the excess structural adhesive flows out from the gaps on the bonding surfaces. Keep the bonding still and wait for the structural adhesive to solidify.

[0082] 13) After the upper and lower skins are glued and cured, a skin shell is formed. The interior of the skin shell is a cavity. Clean the glued area on the outer surface, remove the excess structural glue, and perform appropriate surface quality treatment on the glued area to ensure the appearance effect. At this time, the panel body is only composed of the skin cavity shell and cannot withstand external forces. After the cavity is filled with foam material, it forms an integral structure with the skin shell - the panel body, which has excellent stiffness characteristics. The schematic diagram of the panel body with hollow skin and filled with foam material is shown in the figure. Fig.12 and Fig.13 shown.

[0083] 14) The foaming process of the board body is completed in the foaming tool. The board body shell (hollow state) is placed in the foaming tool. In one embodiment, the method of filling with foam is: injecting liquid polyurethane foam material into the cavity of the skin shell, then sealing the injection hole, placing the skin shell in a constant temperature room of 30℃-55℃, and waiting for the polyurethane foam material to expand and solidify.

[0084] The foaming material used in this embodiment is a liquid two-component polyurethane foaming agent. The mixing and injection of the two-component polyurethane foaming material needs to be completed with the help of a professional polyurethane injection molding machine. The raw materials of the two components are placed in the material tank of the injection molding machine respectively, and the pressure system of the injection machine presses the two components into the mixing chamber of the injection molding machine at a certain mixing ratio (usually a ratio of 1:1) to achieve the mixing of the two components. At the set temperature (the specific value is between 20-40 degrees Celsius), the injection gun nozzle of the injection machine is aimed at the injection hole on the board shell, and the fully mixed polyurethane foaming material is injected. During the injection process, the injection pressure value (the specific value is between 2-8MPa) and the injection time (the specific value is between 10-60 seconds) need to be controlled to complete the injection process of the foaming material in the board cavity. The injection amount of the foaming material is controlled by controlling the injection temperature, pressure value, and injection time of the injection machine. After the injection is completed, seal the injection holes of the board and place it in a constant temperature room of 30℃-55℃ for a specified time (the time is between 30 minutes and 4 hours) to wait for the foaming material to expand and solidify. Fig.14 shown.

[0085] 15) The board body that has completed the foam filling process is removed from the foaming tooling to form the overall structure of the board body of "skin shell + foam core". The surface of the board body is cleaned and repaired to ensure the good appearance of the board body.

[0086] 16) Carry out product quality inspection on the repaired products, apply product logos and serial numbers to qualified products, take good product protection measures, pack them into pre-designed packaging boxes, prepare for product logistics consignment, and the product production process is completed.

[0087] The board body made according to the board body manufacturing process is made of carbon fiber composite material on the outside and foam core material on the inside. Compared with the surfboards produced by traditional processes, it has the advantages of light weight and good rigidity. In addition, since the foam material itself has ideal cushioning performance, when the board body collides, the foam is compressed to absorb energy, which can absorb a large amount of impact energy and avoid structural disintegration, so that the board body has the advantages of anti-collision and energy absorption. At the same time, since the foam material itself is light in weight and has ideal buoyancy characteristics, when the board body collides and impacts, if the board body loses power and the external structure is damaged, the foam material can still provide appropriate buoyancy for the occupants, thereby improving the safety of the board body.

[0088] The above embodiments are only exemplary embodiments of the present application and are not intended to limit the present application. The protection scope of the present application is defined by the claims. Those skilled in the art may make various modifications or equivalent substitutions to the present application within the essence and protection scope of the present application, and such modifications or equivalent substitutions shall also be deemed to fall within the protection scope of the present application.

Claims

1. A process for manufacturing a plate body of a high-speed surface vehicle, characterized in that: The board manufacturing process comprises the following steps: Design the forming mold according to the outer contour of the panel skin; Design the ply angle of carbon fiber prepreg, laminate the carbon fiber prepreg together on the molding die to make a prepreg preform, and then solidify it into a skin; The cured skin is taken out to obtain a skin shell of the panel body, the interior of the skin shell is a cavity, and the cavity of the skin shell is filled with foam to obtain a panel body; The board manufacturing process also includes a design process for the carbon fiber prepreg ply angle: The length direction of the board is used as the 0-degree reference direction for the ply, and the width direction of the board is used as the 90-degree reference direction for the ply. During the ply laying process, the proportion of carbon fiber in the 0-degree direction is controlled at 40%-50% to improve the bending stiffness in the length direction of the board; the proportion of carbon fiber in the 90-degree direction is controlled at 10-20% to improve the stiffness in the lateral direction of the board; the remaining carbon fibers are distributed in the 45-degree and -45-degree directions to improve the torsional stiffness of the board; According to the design process of the carbon fiber prepreg ply angle, the carbon fiber prepregs are laminated together in order, and the first-order non-rigid frequency of the obtained plate is above 80.0 Hz, and the vibration mode of the first-order mode is a bending mode, and the bending is bending in the length direction; After the carbon fiber prepreg ply angle is designed, the carbon fiber prepreg corresponding to the battery compartment position of the board is divided into sheets at different positions according to the battery compartment structure. Notches are provided on the sheets to ensure the coverage of the carbon fiber prepreg at the battery compartment position on the molding mold. The notches of the sheets at different positions are staggered and overlap by 10-20mm.

2. The board manufacturing process of a high-speed surface vehicle according to claim 1 is characterized in that: The board manufacturing process also includes the design process of the forming mold: The panel skin is projected in the horizontal direction, and the panel skin is divided into an upper skin and a lower skin with the maximum projection contour line as the parting line. According to the outer contours of the upper skin and the lower skin, forming molds corresponding to the upper skin and the lower skin are designed respectively.

3. The board manufacturing process of a high-speed surface vehicle according to claim 1, characterized in that: During the curing process, the air inside the prepreg preform formed by paving the carbon fiber prepreg is exhausted so that the internal pores of the prepreg preform are closed under the action of high temperature and high pressure, and the curing reaction occurs to improve the internal density of the cured skin.

4. The process for manufacturing a plate body of a high-speed surface vehicle according to claim 3, characterized in that: The air inside the prepreg preform can be exhausted by a vacuum-assisted autoclave forming process, wherein the vacuum-assisted autoclave forming process comprises: On the prepreg preform, PTFE cloth, perforated PE film and breathable felt are laid in sequence; Install a vacuum nozzle on the vacuum bag, adhere the vacuum bag to the surface of the molding mold, complete the vacuum bag packaging of the prepreg preform, and verify the airtightness of the vacuum bag; The forming mold with the PTFE cloth, the perforated PE film and the breathable felt is installed in the autoclave; Connect the vacuum system in the autoclave to the vacuum nozzle of the vacuum bag, close the autoclave door, monitor the vacuum degree in the vacuum bag, and exhaust the air inside the preform by vacuum adsorption.

5. The process for manufacturing a plate body of a high-speed surface vehicle according to claim 2, characterized in that: Taking out the solidified skin, including the independent upper skin and lower skin, also includes the following operations: removing the auxiliary materials in the process, removing the process edges, applying a protective film to the surface where the skin and the forming mold are bonded for protection, performing interface bonding on the upper skin and the lower skin respectively, and after the interface bonding, performing butt bonding on the upper skin and the lower skin to obtain the skin shell of the panel body.

6. The process for manufacturing a plate body of a high-speed surface vehicle according to claim 1, characterized in that: The board manufacturing process also includes a method of filling with foam: Inject liquid polyurethane foam material into the cavity of the skin shell, then seal the injection hole, place the skin shell in a constant temperature room of 30℃-55℃, and wait for the polyurethane foam material to expand and solidify.

7. The process for manufacturing a plate body of a high-speed surface vehicle according to claim 1, characterized in that: The board manufacturing process also includes a processing method for the forming mold: Before production, the molding mold is surface treated to remove foreign matter on the surface and inspect the surface quality of the molding mold. If the surface quality of the molding mold is normal, apply liquid release agent on the surface of the molding mold, let it stand for 10-30 minutes, wait for the release agent to dry, and then apply 1-2 coats of release agent. The treatment is completed and ready for use.

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