Production process of hydrofoil plate body and electric hydrofoil plate

Abstract

The invention relates to the field of electric hydrofoil plate production, and discloses a hydrofoil plate body production technology and an electric hydrofoil plate. A foaming inner core is provided, and an inner core cavity is formed in the foaming inner core; providing a fiber battery compartment and a battery compartment mold, putting the fiber battery compartment into the battery compartment mold, and integrally foaming to integrally form a battery compartment module; and after the whole periphery and the bottom of the side face of the battery bin module and the inner side wall of the inner core cavity are coated with an adhesive, the battery bin module is placed into the inner core cavity of the foaming inner core, curing combination is conducted, and an initial hydrofoil plate body is formed. The battery compartment module is formed by foaming in the mold, so that high density and high filling rate between the foaming material and the battery compartment can be ensured, and good waterproof performance is realized; through a modular assembly mode, the installation of different plate bodies is compatible; therefore, the characteristics of mould pressing foaming and flexible manufacturing are realized at lower cost, and the reliability of the plate body is greatly improved.

Description

Technical Field

[0001] The invention relates to the field of electric hydrofoil board production, and in particular to a production process of a hydrofoil board body and an electric hydrofoil board. Background Art

[0002] As a kind of water sports and leisure equipment, electric hydrofoil board (efoil) has been favored by more and more water sports enthusiasts in recent years because it can bring people the unique experience of "flying like a sword" underwater; the board body is one of the main parts of the electric hydrofoil board. This part generally adopts the process of foam core + fiber + epoxy resin infiltration and curing to achieve product lightweight.

[0003] See also Figure 1 to Figure 6 At present, the foaming core of the hydrofoil board body is processed by two processing technologies: the first is compression foaming, in which the foaming core 100 is directly foamed in the mold, with high molding precision and high production efficiency. However, if different types of boards are to be made, corresponding core foaming molds need to be opened, which is costly. The second is to form the foam blank by CNC machining. The molding precision is not as good as compression molding, but the manufacturing is flexible, the core does not need to be molded, and the cost is low. Because of the molding precision problem of this process, the battery compartment 200 is generally made into an independent part for secondary assembly. In order to ensure normal installation, a large assembly gap or avoidance space 400 is reserved in the central cavity 300 of the foaming core (because the battery compartment adopts the fiber hand-paste molding process, the dimensional tolerance is also large); the gap between the battery compartment and the foaming core is generally filled with room temperature or low temperature self-foaming materials, and the filling effect after foaming is used to fill the gap between the battery compartment and the foaming core. This self-foaming gap filling process has the following obvious disadvantages:

[0004] 1. Low density and not waterproof. If the outer fiber is damaged, water can easily penetrate into it and cannot be precipitated out, resulting in high humidity inside the board. After a period of time, the strength of the fiber battery compartment will decrease and soften and bulge.

[0005] 2. The filling rate is low. Because it is self-foaming, the molding pressure is far less than that of in-mold foaming. And because of some corners and crannies caused by the structure of the fiber battery compartment, it is impossible to ensure that the gap between the foaming core and the fiber compartment body after assembly is well filled, and it is undetectable. It is difficult to avoid the generation of internal cavities. The air inside these cavities will also cause bulging of the board when the temperature rises. Summary of the invention

[0006] The purpose of the present invention is to overcome the shortcomings of the prior art and provide a production process for a hydrofoil plate and an electric hydrofoil plate, which are formed by in-mold foaming of a battery compartment module, thereby ensuring high density and high filling rate between the foaming material and the battery compartment, thereby achieving good waterproof performance; through modular assembly, it is compatible with different plate installations; thereby achieving the characteristics of molded foaming and flexible manufacturing at a lower cost, greatly improving the reliability of the plate.

[0007] The objective of the present invention is achieved through the following technical solutions:

[0008] A production process for a hydrofoil plate body comprises the following steps:

[0009] S10, providing a foamed inner core, wherein the foamed inner core is provided with an inner core cavity;

[0010] S20, providing a fiber battery compartment and a battery compartment mold, placing the fiber battery compartment into the battery compartment mold, foaming the entire fiber battery compartment, and forming the entire fiber battery compartment into a battery compartment module;

[0011] S30, after applying adhesive to the entire circumference of the side, the bottom and the inner wall of the inner core cavity of the battery compartment module, the battery compartment module is placed in the inner core cavity of the foamed inner core, and cured and bonded to form an initial hydrofoil plate body;

[0012] S40, laying a fiber reinforcement layer on the surface of the initial hydrofoil plate body, and forming a fiberized hydrofoil plate body after the impregnated glue is cured and polished smooth;

[0013] S50, performing appearance protection coating on the fiberized hydrofoil plate body to finally form the hydrofoil plate body.

[0014] In one embodiment, the step of applying an appearance protective coating to the fiberized hydrofoil plate body specifically includes:

[0015] The fiberized hydrofoil plate body is painted or the surface is laid and cured, and polished to form a polished plate body;

[0016] The polished plate body is protected in appearance, coated with glue, heated and cured, and ground to form a final hydrofoil plate body.

[0017] In one embodiment, after the step of performing appearance protection coating on the fiberized hydrofoil plate body, the method further comprises:

[0018] S60, assembling external parts of the hydrofoil plate body to complete the production of the plate body.

[0019] In one of the embodiments, the battery compartment module is a stepped battery compartment module;

[0020] In step S30, adhesive is applied to the entire circumference of the side surface and the step surface of the stepped battery compartment module.

[0021] In one embodiment, the adhesive is epoxy resin.

[0022] In one of the embodiments, the battery compartment module is made of one of aramid, glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend, or any mixture thereof.

[0023] In one embodiment, the molding process of the battery compartment module adopts compression molding or vacuum overmolding.

[0024] In one embodiment, in step S40, the fiber reinforcement layer is made of one of Kevlar (aramid), glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend, or any combination thereof.

[0025] In one embodiment, the fiber reinforcement layer includes a glass fiber layer and a carbon fiber layer disposed on the glass fiber layer.

[0026] The present invention also provides an electric hydrofoil plate, which is manufactured using any one of the production processes described above.

[0027] The advantages and beneficial effects of the present invention compared to the prior art are as follows:

[0028] 1. The present invention is a production process for a hydrofoil plate and an electric hydrofoil plate, wherein the fiber battery compartment is placed in a battery compartment mold, foamed as a whole, and formed as a battery compartment module as a whole; and adhesive is applied to the entire periphery of the side, the bottom, and the inner wall of the inner core cavity of the battery compartment module, and then cured and combined to form. That is, the battery compartment module is formed in the form of foaming in the mold, which can ensure high density and high filling rate between the foaming material and the battery compartment, thereby achieving good waterproof performance; through modular assembly, it is compatible with different board installations; thereby, the reliability of the board is greatly improved with lower cost and the characteristics of molded foaming and flexible manufacturing.

[0029] 2. The hydrofoil plate body of the present invention adopts a modular design, and is compatible with different plate bodies through the battery compartment module, thus realizing platformization and greatly reducing costs. The battery compartment module of the present invention adopts the form of placing the fiber compartment body into the mold for foaming, which achieves a high filling rate and high density, and effectively blocks the water infiltration path, thereby improving the waterproof performance of the plate body. The battery compartment module of the present invention, due to its high filling rate and high density, has no obvious cavity inside the module, has good air tightness, ensures the structural strength of the body, improves reliability, and prolongs service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of an electric hydrofoil plate in the prior art (I);

[0031] Figure 2 It is a structural schematic diagram of an electric hydrofoil plate in the prior art (II);

[0032] Figure 3 The schematic diagram of the structure of the electric hydrofoil plate in the prior art (III)

[0033] Figure 4 for Figure 3 A cross-sectional view of the electric hydrofoil panel shown along the AA and BB directions;

[0034] Figure 5 for Figure 3 A cross-sectional view of the electric hydrofoil panel shown along the CC direction;

[0035] Figure 6 This is a schematic diagram of the structure of two boards with different shapes that use the same modular battery compartment;

[0036] Figure 7 It is a schematic diagram of the exploded structure of an electric hydrofoil plate according to one embodiment of the present invention;

[0037] Figure 8 It is a schematic structural diagram of an electric hydrofoil plate according to one embodiment of the present invention;

[0038] Fig. 9 It is a structural schematic diagram of a battery compartment module of an electric hydrofoil board according to an embodiment of the present invention;

[0039] Fig.10 It is a structural schematic diagram of a battery compartment module of an electric hydrofoil board according to another embodiment of the present invention;

[0040] Fig.11 The present invention is a flowchart of a production process of a hydrofoil plate according to an embodiment of the present invention. DETAILED DESCRIPTION

[0041] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0042] See also Figure 7 to Figure 11 , a production process of a hydrofoil plate body, comprising the following steps:

[0043] S10, providing a foamed inner core, wherein the foamed inner core is provided with an inner core cavity;

[0044] It should be noted that, first, a foam core is prepared as the basic structure of the hydrofoil board. An inner core cavity is opened inside the foam core, which not only provides assembly space for subsequent components, but also provides basic buoyancy and structural support for the entire hydrofoil board through its light weight and high strength characteristics.

[0045] Specifically, select lightweight and high-strength foam materials that meet the requirements, and use mold forming technology to accurately produce a foam core with a specific shape and size. During the molding process, ensure that the inner core cavity opened inside the inner core has accurate dimensions and a smooth surface, providing an accurate reference for the assembly of subsequent components. At the same time, the inner core is subjected to necessary pretreatment, such as cleaning and dust removal, to ensure the smooth progress of subsequent processes.

[0046] S20, providing a fiber battery compartment and a battery compartment mold, placing the fiber battery compartment into the battery compartment mold, foaming the entire fiber battery compartment, and forming the entire fiber battery compartment into a battery compartment module;

[0047] It should be noted that this step is the production of the battery compartment module. The battery compartment is made of fiber material and equipped with a corresponding battery compartment mold. The fiber battery compartment is accurately placed in the mold, and the fiber and foaming material are closely combined through the overall foaming technology to form a light and strong battery compartment module. This step not only ensures the sealing and safety of the battery compartment, as well as the high-strength structure, but also improves the overall energy efficiency of the hydrofoil board by optimizing the layout.

[0048] Specifically, high-performance fiber materials (such as carbon fiber, glass fiber, etc.) are selected, and are precisely cut and woven into the outer shell of the battery compartment according to the design drawings of the battery compartment. Subsequently, the fiber battery compartment is placed in a specially designed battery compartment mold, and an appropriate amount of foaming material is injected. Through the overall foaming technology, the fiber and the foaming material are tightly combined and integrated into a battery compartment module. During the foaming process, parameters such as temperature and pressure are strictly controlled to ensure that the density, strength and sealing of the battery compartment module meet the design requirements.

[0049] S30, after applying adhesive to the entire circumference of the side, the bottom and the inner wall of the inner core cavity of the battery compartment module, the battery compartment module is placed in the inner core cavity of the foamed inner core, and cured and bonded to form an initial hydrofoil plate body;

[0050] It should be noted that this step is structural integration and curing. Special adhesive is evenly applied to the entire side and bottom of the battery compartment module, and a corresponding adhesive layer is also applied to the inner wall of the inner core cavity of the foamed inner core. After this preparatory work is completed, the battery compartment module is accurately embedded in the inner core cavity, and through a specific curing process, the two are tightly combined into an inseparable whole-the initial hydrofoil plate. The key to this step is to ensure seamless docking between the components, thereby providing stable structural support. In this embodiment, the entire side of the battery compartment module is the side walls of the battery compartment module. The surrounding side walls and bottom of the battery compartment module need to be coated with adhesive.

[0051] Specifically, apply special adhesive evenly around the sides and bottom of the battery compartment module and the inner wall of the inner core cavity of the foamed inner core. When applying, pay attention to controlling the amount and distribution of the adhesive to ensure that the components fit tightly. Then, accurately embed the battery compartment module into the inner core cavity and fix its position with a clamp or positioning device. During the curing process, strictly control parameters such as temperature and time to fully cure the adhesive and form a strong bond to ensure the overall stability of the initial hydrofoil board.

[0052] S40, laying a fiber reinforcement layer on the surface of the initial hydrofoil plate body, and forming a fiberized hydrofoil plate body after the impregnated glue is cured and polished smooth;

[0053] It should be noted that this step is fiber reinforcement treatment; multiple fiber reinforcement layers are laid on the surface of the initial hydrofoil body, and these reinforcement layers are precisely coated or cut and positioned to ensure maximum reinforcement effect in key areas. Resin glue is impregnated between the fiber reinforcement layers. After the curing process, it not only enhances the overall strength and rigidity of the hydrofoil body, but also makes its surface smooth as a mirror through fine grinding, reducing water flow resistance and improving movement efficiency.

[0054] Specifically, multiple layers of fiber reinforcement layers are laid on the surface of the initial hydrofoil board body according to the design requirements. The fiber reinforcement layer is not limited to the selection of materials such as carbon fiber and glass fiber. Through precise cutting and positioning, ensure that the layers are tightly fitted and in the same direction. During the laying process, pay attention to controlling the thickness and density of the fiber layer to meet the strength and stiffness requirements of the hydrofoil board body. Subsequently, high-performance resin glue is impregnated between the fiber layers, and the resin glue is fully cured through a specific heating and curing process to tightly combine the fiber layers together to form a fiberized hydrofoil board body. Finally, the fiberized hydrofoil board body is finely polished to remove burrs and unevenness on the surface, ensure that its surface is as smooth as a mirror, and reduce water flow resistance.

[0055] S50, performing appearance protection coating on the fiberized hydrofoil plate body to finally form the hydrofoil plate body.

[0056] It should be noted that this step is for appearance protection and final shaping. The appearance protection treatment of the fiberized hydrofoil board includes but is not limited to coating with wear-resistant and corrosion-resistant protective coatings, and adding colors or patterns as required to enhance the aesthetics and recognition. This step not only protects the hydrofoil board from environmental factors, but also through process treatment, makes the final hydrofoil board have both functionality and beauty, becoming the most beautiful water sports equipment.

[0057] Specifically, the fiberized hydrofoil body is treated with appearance protection. First, according to the design requirements, a wear-resistant and corrosion-resistant protective coating material is selected and evenly coated on the surface of the hydrofoil body by spraying, brushing, etc. During the coating process, pay attention to controlling the thickness and uniformity of the coating to ensure its protective effect. Subsequently, color or pattern is added as required to enhance the aesthetics and recognition. Finally, the coated hydrofoil body is subjected to necessary inspection and testing to ensure that its performance and appearance meet the design requirements to form the final hydrofoil body product.

[0058] In this way, the fiber battery compartment is placed in the battery compartment mold, foamed as a whole, and formed into a battery compartment module as a whole; and the adhesive is applied to the entire periphery of the side, the bottom and the inner wall of the inner core cavity of the battery compartment module, and then cured and combined. That is, the battery compartment module is formed in the form of foaming in the mold, which can ensure high density and high filling rate between the foaming material and the battery compartment, thereby achieving good waterproof performance; through modular assembly, it is compatible with different board installations; thus, the reliability of the board is greatly improved at a lower cost and with the characteristics of molded foaming and flexible manufacturing.

[0059] It should be noted that the step of applying a protective coating to the appearance of the fiberized hydrofoil plate specifically includes:

[0060] S51, coating or surface laying and curing the fiberized hydrofoil plate body, and polishing the plate body to form a polished plate body;

[0061] It should be noted that the detailed painting or appearance laying of the fiberized hydrofoil body may involve the application of primer to enhance the adhesion of the subsequent protective layer. After the painting is completed, the curing treatment is carried out to make the coating and the fiberized hydrofoil body tightly bonded. Subsequently, the coating surface is finely polished with a grinding tool to remove any unevenness or defects to form a smooth and delicate polished board body. This step not only improves the touch and visual effect of the hydrofoil body, but also provides an ideal base for the subsequent protective coating.

[0062] S52, protecting the appearance of the polished plate body, coating it with glue, heating and curing it, and grinding it to form a final hydrofoil plate body.

[0063] It should be noted that the key step in appearance protection based on the polished board is to apply glue. The glue here refers to a high-performance, corrosion-resistant, and wear-resistant protective coating material, which can effectively isolate the external environment from erosion of the fiberized hydrofoil board. When applying, it is necessary to ensure that the coating is uniform and without omissions to form a continuous protective barrier. After the coating is completed, the coating is heated and cured to allow the coating material to fully cross-link and cure to form a strong and durable protective layer. Finally, the cured coating is ground again to eliminate minor defects that may occur during the curing process to ensure that the final surface of the hydrofoil board is flawless.

[0064] Furthermore, after the step of applying a protective coating to the appearance of the fiberized hydrofoil plate, the method further comprises:

[0065] S60. Assemble the external parts of the hydrofoil board to complete the board production. It should be noted that after the exterior protective coating is completed, the final assembly stage of the hydrofoil board is entered. This stage includes the installation of necessary external parts such as connectors, fixtures, sensors, etc. These parts not only provide the hydrofoil board with connection points with other systems or structures, but also ensure its stable operation in complex environments. During the assembly process, the design drawings and assembly specifications must be strictly followed to ensure the precise positioning and firm connection of each component, so as to form a complete and fully functional hydrofoil board.

[0066] It should also be noted that the battery compartment module is a stepped battery compartment module; in step S30, adhesive is applied to the entire circumference of the side and the stepped surface of the stepped battery compartment module. In this embodiment, the adhesive is preferably epoxy resin, and of course other glues with the same function can also be used as a substitute.

[0067] It should be noted that the stepped battery compartment module adopts a multi-level, stepped structural design, which not only optimizes the internal spatial layout of the battery compartment, improves the density and efficiency of energy storage, but also provides a more stable support surface for the combination of the battery compartment module and the foam core. The stepped structural characteristics enable the battery compartment module to be more tightly embedded in the inner core cavity of the foam core, reducing the gap during the assembly process and enhancing the overall structural strength.

[0068] Specifically, in step S30, the adhesive is carefully applied to the entire circumference of the side and each step surface of the stepped battery compartment module. In this step, the adhesive selected is epoxy resin, which is known for its strong bonding strength, good chemical corrosion resistance and excellent electrical properties. Epoxy resin can firmly combine the battery compartment module with the foam core to form an inseparable whole structure. When applying, it is necessary to ensure that the adhesive evenly covers the entire circumference of the side and step surface of the battery compartment module, leaving no dead corners, so as to ensure the complete sealing and stability of the bonding surface.

[0069] The stepped battery compartment module is tightly bonded to the foam core through epoxy resin adhesive to form a stable internal structure. This bonding method not only improves the overall strength and rigidity of the hydrofoil board, but also ensures the stable operation of the battery compartment module in complex environments, preventing loosening or damage caused by vibration or impact. As the key material for connecting the stepped battery compartment module and the foam core, epoxy resin adhesive plays a vital role. It not only provides strong bonding force to ensure a close fit between the two, but also protects the battery compartment module from erosion by the external environment through its chemical corrosion resistance and electrical properties, thereby extending the service life of the hydrofoil board.

[0070] The design of the stepped battery compartment module and the application of epoxy resin adhesive together constitute the key points in the manufacturing process of the hydrofoil board. They not only improve the overall performance and stability of the hydrofoil board, but also provide a solid foundation for subsequent assembly and use, ensuring the efficient operation of the hydrofoil board in various complex environments and improving reliability.

[0071] In addition, the battery compartment module is made of one of aramid, glass fiber, carbon fiber, carbon-aromatic blend, carbon-glass blend, or any mixture thereof. Furthermore, the molding process of the battery compartment module adopts compression molding or vacuum overmolding. It should be noted that as one of the core components of the electric hydrofoil board, the battery compartment module can be constructed of one of high-strength, lightweight materials such as aramid, glass fiber, carbon fiber, carbon-aromatic blend (carbon fiber and aramid blend), carbon-glass blend (carbon fiber and glass fiber blend) or any mixture thereof. These materials provide a solid protective barrier for the battery compartment with their excellent mechanical properties, such as high strength, high modulus, strong fatigue resistance and corrosion resistance. In terms of molding process, the battery compartment module adopts compression molding or vacuum overmolding technology. Compression molding uses a mold to treat the prepreg at high temperature and high pressure to ensure that the material is tightly fitted and forms a complex three-dimensional structure; while vacuum overmolding uses a vacuum environment to remove excess resin to form a component with a smooth surface and a dense structure. Both processes can effectively improve the strength and precision of the battery compartment module, while reducing material waste and improving production efficiency.

[0072] Furthermore, in step S40, the fiber reinforcement layer is made of one of Kevlar (aramid), glass fiber, carbon fiber, carbon-aromatic blend, carbon-glass blend, or any combination thereof. It should be noted that in step S40, the fiber reinforcement layer is also made of one of high-performance materials such as Kevlar (aramid), glass fiber, carbon fiber, carbon-aromatic blend, carbon-glass blend, or any combination thereof. The selection of these materials is intended to further enhance the structural strength, impact resistance, and durability of the hydrofoil. Kevlar is known for its extremely high tensile strength and wear resistance, and can effectively resist external impacts; glass fiber provides good tensile strength and cost-effectiveness; and carbon fiber, with its light weight and high strength characteristics, significantly improves the overall rigidity and motion performance of the hydrofoil. The mixed material combines the advantages of different fibers and improves tensile capacity.

[0073] In this embodiment, the fiber reinforcement layer includes a glass fiber layer and a carbon fiber layer disposed on the glass fiber layer. It should be noted that the glass fiber layer and the carbon fiber layer are tightly bonded by the infiltration and curing of high-performance resin glue. The resin glue not only fills the tiny gaps between the fibers, but also firmly connects the two layers of fibers together through chemical reactions to form a continuous, high-strength composite structure. The glass fiber layer and the carbon fiber layer complement each other in mechanical properties. The glass fiber layer provides strong toughness and effectively resists damage during long-term use; and the carbon fiber layer, with its excellent stiffness and strength, enhances the stability of the hydrofoil body under high-speed movement or extreme conditions.

[0074] In this way, through the combination of glass fiber layer and carbon fiber layer, the overall strength and stiffness of the hydrofoil board body are significantly improved, and it can withstand greater loads and more drastic dynamic changes, ensuring the stable operation of the hydrofoil board body in various complex environments. The addition of the carbon fiber layer enables the hydrofoil board body to achieve significant lightweight while maintaining high strength and high stiffness. This not only improves the movement efficiency of the hydrofoil board body, but also reduces energy consumption and extends the service life of the equipment. The synergistic effect of the glass fiber layer and the carbon fiber layer enables the hydrofoil board body to show good durability in long-term use. Together, they resist the erosion of external environments such as water, air, and salt, ensuring the long-term stability and reliability of the hydrofoil board body. The fiber-reinforced layer achieves a comprehensive improvement in the strength, stiffness, lightweight and durability of the hydrofoil board body through the combination of the glass fiber layer and the carbon fiber layer, providing a solid foundation for the manufacture of high-performance hydrofoil boards.

[0075] The present invention also provides an electric hydrofoil board, which is manufactured by any of the above-mentioned production processes. Figure 7 to Figure 9The electric hydrofoil board includes: a foamed inner core 10, a battery compartment module 20 and an outer surface component, and an inner core cavity 11 is provided on the foamed inner core 10; it should be noted that the foamed inner core 10 is the main structure of the hydrofoil board, and the foamed inner core 10 is made of a lightweight and high-strength foamed material, and an inner core cavity 11 is provided inside it. This not only reduces the overall weight, but also provides the necessary buoyancy and structural support. The inner side wall of the inner core cavity 11 is carefully processed and coated with a uniform epoxy resin layer 30 as an adhesive, which provides a reliable connection basis for the subsequent embedding of the battery compartment module. Furthermore, the battery compartment module 20 includes a fiber battery compartment 21 and an in-membrane foaming structure 22, and the fiber battery compartment 21 is arranged on the in-membrane foaming structure 22, and the fiber battery compartment 21 and the in-membrane foaming structure 22 are an integrally formed structure.

[0076] The battery compartment module 20 is coated with adhesive around and on the bottom, and the inner side wall of the inner core cavity of the foamed inner core is also coated with adhesive. The battery compartment module 20 is embedded in the inner core cavity 11 by the adhesive, and the adhesive is an epoxy resin layer 30; it should be noted that the battery compartment module 20, as the power source of the hydrofoil board, is coated with an epoxy resin layer 30 around and on the bottom. This layer of adhesive not only enhances the sealing of the battery compartment module, but also ensures the close fit between it and the inner core cavity 11 of the foamed inner core 10. Through the curing action of the epoxy resin, the battery compartment module 20 is firmly embedded in the inner core cavity 11, forming a safe and efficient energy storage unit. The foamed inner core 10, the battery compartment module 20 and the outer surface components are closely connected by the adhesive force of the epoxy resin layer 30 to form an integral structure. This not only improves the torsional strength and impact resistance of the hydrofoil board, but also ensures the close fit between the components.

[0077] The outer surface component includes a fiber reinforcement layer 40 , a coating appearance layer 50 and an appearance protection layer 60 , the fiber reinforcement layer 40 is coated on the foam core 10 , the coating appearance layer 50 is attached to the fiber reinforcement layer 40 , and the appearance protection layer is wrapped on the coating appearance layer 50 .

[0078] It should be noted that the fiber reinforcement layer 40 is used as the outer protection of the hydrofoil board. The fiber reinforcement layer 40 adopts high-performance glass fiber and carbon fiber composite materials and is coated on the foam core 10 through a specific process. This layer not only provides additional structural strength, but also enhances the impact resistance and durability of the hydrofoil board. A coating appearance layer 50 is attached on the fiber reinforcement layer 40. This layer not only gives the hydrofoil board a unique visual beauty, but also enhances the product's recognition and attractiveness through the design of colors and patterns. In order to further enhance the durability of the hydrofoil board, the appearance protection layer 60 is wrapped on the coating appearance layer 50. This layer is made of wear-resistant and weather-resistant materials, which effectively resists scratches, corrosion and other damages in daily use, thereby extending the service life.

[0079] The battery compartment module 20 provides long-lasting and stable power support for the hydrofoil board; the fiber reinforcement layer 40 enhances the strength and rigidity of the overall structure; the paint appearance layer 50 and the appearance protection layer 60 together enhance the aesthetics and durability of the product.

[0080] In this way, the electric hydrofoil board of the present invention is formed into a battery compartment module by placing the fiber battery compartment into a battery compartment mold, foaming the whole body, and applying an epoxy resin layer to the entire circumference of the side, the bottom, and the inner wall of the inner core cavity of the battery compartment module, and then curing and combining them. That is, the battery compartment module is formed in the form of foaming in the mold, which can ensure high density and high filling rate between the foaming material and the battery compartment, thereby achieving good waterproof performance; through modular assembly, it is compatible with different board installations; thus, the reliability of the board is greatly improved with lower cost and the characteristics of molded foaming and flexible manufacturing.

[0081] It can be understood that the in-film foam structure 22 is a step structure, and the battery compartment module 20 also includes a plurality of S-shaped limit blocks 23, each of which is respectively arranged on the step surface of the in-film foam structure, and correspondingly, a plurality of S-shaped limit grooves 24 are provided on the inner core cavity of the foam inner core 10, and each of the S-shaped limit blocks is respectively embedded in each of the S-shaped limit grooves in a one-to-one correspondence; preferably, the battery compartment module 20 also includes at least three S-shaped limit blocks, and the three S-shaped limit blocks are connected to form a triangular structure. In this way, on the one hand, the limit can be achieved, and on the other hand, it can be quickly installed.

[0082] It should be noted that the intra-membrane foaming structure 22 is a stepped structure, which ensures the stability and durability of the structure. The S-shaped limit block 23 is used to accurately match the limit groove of the foaming inner core. The S shape can be used to provide stable support and positioning. The S-shaped limit groove opened on the foaming inner core cavity is embedded in a one-to-one correspondence with the S-shaped limit block. This structure further ensures the precise positioning and stability of the battery compartment module during installation and use. The shape of the limit groove matches the limit block, so that the limit block can be smoothly embedded, reducing friction and wear during installation. In addition, it is preferred that at least three S-shaped limit blocks are connected to form a triangular structure, and this layout provides a more stable support. The triangular structure has high stability due to its geometric characteristics, so that the battery compartment module can evenly disperse the pressure when subjected to external force, reduce local stress concentration, and thus improve the stability and durability of the overall structure. In this way, the use of the S-shaped limit block and the limit groove ensures the precise positioning of the battery compartment module during installation, reduces installation errors, and improves the stability of the overall structure. The design of the S-shaped limit blocks allows for a quick and easy installation process as they fit smoothly into the limit slots, reducing installation time and labor intensity. The triangular structure of the S-shaped limit block layout enhances the structural strength of the battery compartment module, enabling it to withstand greater mechanical stress, and improves the durability and reliability of the battery compartment module. Through precise positioning and a stable structural design, the safety of the battery compartment module during use is improved, reducing potential risks caused by improper installation or structural instability. Due to the precise fit between the limit blocks and the limit slots, alignment during installation is faster and more accurate, greatly improving the installation efficiency of the battery compartment module. The limit blocks are connected to form a triangular structure. The triangular structure has high stability due to its geometric characteristics, which enables the battery compartment module to evenly disperse pressure when subjected to external forces, reduce local stress concentration, and thus improve the stability and durability of the overall structure.

[0083] Furthermore, an epoxy resin layer is also coated on the outer surfaces of multiple S-shaped limit blocks and the inner surfaces of multiple S-shaped limit grooves, so as to ensure the stable connection between the S-shaped limit blocks and the S-shaped limit grooves, strengthen the fixing effect, and improve the reliability. In this way, the coating of the epoxy resin layer provides additional bonding strength for the S-shaped limit blocks and the limit grooves. This high-strength bonding effect makes the limit blocks more securely fixed in the limit grooves, reducing the risk of displacement caused by vibration or impact. The high adhesion performance of epoxy resin ensures a tight bond between the S-shaped limit blocks and the limit grooves. This bond not only provides mechanical stability, but also enhances the fixing effect through chemical bonding, making the structure of the entire battery compartment module more stable. The addition of the epoxy resin layer makes the S-shaped limit blocks more securely embedded in the limit grooves, improving the reliability of the entire battery compartment module in long-term use, especially the durability when subjected to repeated mechanical stress.

[0084] Furthermore, the combination of the S-shaped limit block and the limit groove forms a mechanical and chemical double locking structure. The addition of the epoxy resin layer makes this double locking more effective, ensuring the precise positioning and long-term stability of the limit block in the limit groove. As a high-performance adhesive material, the epoxy resin layer is tightly combined with the surface of the foaming structure, providing the S-shaped limit block with additional shear and tensile resistance. This interaction significantly improves the structural strength of the battery compartment module. Through the protection of the epoxy resin layer, the S-shaped limit block and the limit groove not only achieve a physically stable connection, but also can resist chemical corrosion and environmental influences such as humidity, temperature changes, etc., thereby extending the service life and maintenance cycle of the battery compartment module.

[0085] Specific process flow of the present invention:

[0086] In this embodiment, the foamed inner core 10 is formed by CNC processing without the need for mold opening, and an inner core cavity 11 is processed in the middle.

[0087] In this embodiment, the battery compartment module 20 adopts an in-mold foaming process, and the fiber battery compartment is placed together in the membrane for overall foaming, thereby achieving a higher filling rate and filling density. Compared with the existing solution (self-foaming to fill the assembly gap), the production efficiency and yield rate are greatly improved.

[0088] Furthermore, the battery compartment module 20 in this embodiment is made of a certain number of layers of glass fiber material + vacuum molding process. In other embodiments, it can be a certain number of layers of Kevlar (aramid), glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend and other fibers. It can be made of mixed fibers or a single fiber. The molding process can be compression molding or vacuum molding.

[0089] In this embodiment, the battery compartment module 20 is placed into the inner core cavity 11, and the two are bonded together by curing the epoxy resin layer 30 coated on the entire circumference of the side and the step surface. Because the peel strength / shear strength generated by the epoxy resin after curing is much higher than the bonding strength of the foam material, the bonding point has a higher connection reliability.

[0090] In this embodiment, the battery compartment module 20 is designed as a regular polyhedron structure. Correspondingly, the inner core cavity 11 is easy to process and can easily obtain a higher assembly accuracy. It only needs to flow out to accommodate the epoxy resin in micro-spaces. Compared with the existing solutions, the positioning accuracy and production efficiency are greatly improved.

[0091] Furthermore, after the battery compartment 20 is assembled and the epoxy resin 30 is cured, a fiber reinforcement layer 40 is laid on the surface of the foamed inner core 10, and after the impregnated glue is cured and polished, the board body has a strength within the design specification. In this embodiment, the fiber reinforcement layer is a certain number of layers of glass fiber and carbon fiber material, in which the carbon fiber material is an independent layer. In other embodiments, the fiber reinforcement layer can be a certain number of layers of Kevlar (aramid), glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend, etc. It can be made of mixed fibers or a single fiber, and can all be called a fiber reinforcement layer.

[0092] Furthermore, after the coating or appearance layer 50 is laid, cured, and polished smooth, the board body has an appearance that meets the design requirements;

[0093] Furthermore, the appearance protection layer 60 is generally covered with a coating glue, and after the glue is heated and cured, it is carefully ground to be bright and transparent with a glass texture, and the basic production process of the board is completed;

[0094] Furthermore, the remaining parts of the board are assembled and the board is manufactured, wherein the parts include but are not limited to handles, foot pads, air pads and battery pads.

[0095] The electric hydrofoil board applied for in the present invention adopts a modular design, and is compatible with different board bodies through the battery compartment module, thus realizing platformization, thereby greatly reducing costs. The battery compartment module applied for in the present invention adopts the form of placing the fiber compartment body into the mold for foaming, so as to achieve a high filling rate and high density, and effectively block the water infiltration path, thereby improving the waterproof performance of the board body. The battery compartment module of the present invention, due to its high filling rate and high density, has no obvious cavity inside the module, has good air tightness, ensures the structural strength of the body, improves reliability, and prolongs service life.

[0096] The electric hydrofoil board of the present invention adopts a platform and modular design, which is compatible with different types of boards, greatly shortening the R&D cycle and reducing the mold opening cost. Figure 6 Although the two boards have different shapes, they use the same modular battery compartment. The modular board of the present invention has excellent waterproof performance, avoiding the risk and problem of self-foaming materials easily hiding water and poor filling rate causing board bulging.

[0097] The above-mentioned embodiments only express several embodiments of the present invention, and the description is relatively specific and detailed, but it cannot be understood as limiting the scope of the patent of the present invention. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the present invention, which all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be based on the attached claims.

Claims

1. A production process for a hydrofoil plate, characterized in that: The steps include: S10, providing a foamed inner core, wherein the foamed inner core is provided with an inner core cavity; S20, providing a fiber battery compartment and a battery compartment mold, placing the fiber battery compartment into the battery compartment mold, foaming the entire fiber battery compartment, and forming the entire fiber battery compartment into a battery compartment module; S30, after applying adhesive to the entire circumference of the side, the bottom and the inner wall of the inner core cavity of the battery compartment module, the battery compartment module is placed in the inner core cavity of the foamed inner core, and cured and bonded to form an initial hydrofoil plate body; S40, laying a fiber reinforcement layer on the surface of the initial hydrofoil plate body, and forming a fiberized hydrofoil plate body after the impregnated glue is cured and polished smooth; S50, performing appearance protection coating on the fiberized hydrofoil plate body to finally form the hydrofoil plate body.

2. The production process of the hydrofoil plate according to claim 1, characterized in that: The step of applying appearance protection coating to the fiberized hydrofoil plate body specifically comprises: The fiberized hydrofoil plate body is painted or the surface is laid and cured, and polished to form a polished plate body; The polished plate body is protected in appearance, coated with glue, heated and cured, and ground to form a final hydrofoil plate body.

3. The production process of the hydrofoil plate according to claim 1 or 2, characterized in that: After the step of applying appearance protection coating to the fiberized hydrofoil plate body, the method further comprises: S60, assembling external parts of the hydrofoil plate body to complete the production of the plate body.

4. The production process of the hydrofoil plate according to claim 1, characterized in that: The battery compartment module is a stepped battery compartment module; In step S30, adhesive is applied to the entire circumference of the side surface and the step surface of the stepped battery compartment module.

5. The production process of the hydrofoil plate according to claim 1 or 4, characterized in that: The adhesive is epoxy resin.

6. The production process of the hydrofoil plate according to claim 1, characterized in that: The battery compartment module is made of one of aramid, glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend, or any mixture thereof.

7. The production process of the hydrofoil plate according to claim 6, characterized in that: The battery compartment module is formed by compression molding or vacuum molding.

8. The production process of the hydrofoil plate according to claim 1, characterized in that: In step S40, the fiber reinforcement layer is made of one of Kevlar (aramid), glass fiber, carbon fiber, carbon-aramid blend, carbon-glass blend, or any combination thereof.

9. The production process of the hydrofoil plate according to claim 8, characterized in that: The fiber reinforcement layer includes a glass fiber layer and a carbon fiber layer arranged on the glass fiber layer.

10. An electric hydrofoil board, characterized in that: The invention is produced by the production process described in any one of claims 1 to 9.

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