Integrated fiber forming process for surfboard

Abstract

The invention relates to the field of surfboards, in particular to an integrated fiber forming process for a surfboard, which is characterized in that an adjustable modular mold is selected, and an electric heating element with a PLC (programmable logic controller) intelligent control system is integrated in the mold to realize heating and temperature control of the mold; carbon fiber prepreg of a rapid curing resin system is selected, and aramid fibers or basalt fibers are added between carbon fiber layers, so that the hybrid fiber composite material is formed. According to the invention, through the design of a modular mold with a built-in heating system, the prepreg can be produced in an integrated molding manner, and the application of a novel material is combined with an intelligent control technology, so that the structural strength and the production efficiency of the product are improved; and moreover, the quality consistency and the environmental protection property of finished products are ensured, the overall performance of the plate body is improved, the production process is simplified, and the cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of surfboards, and in particular to a fiber integrated molding process for surfboards. Background Art

[0002] A powered surfboard is a water sports device that combines a surfboard with an electric propulsion system. It usually has a streamlined design and is made of lightweight and strong materials to ensure good buoyancy and durability.

[0003] Traditional powered surfboards on the market often have certain disadvantages during the manufacturing process, such as: 1. The traditional process uses a method in which multiple parts are formed separately and then bonded together, which makes the connection parts the weak link of the structure, prone to delamination and cracking, reducing the overall strength and durability.

[0004] 2. The traditional process has multiple bonding and assembly steps that are complicated, which increases the production cycle and labor costs, and is difficult to meet the needs of large-scale production.

[0005] 3. Traditional processes are often manual operations, and the uncontrollable factors of manual operations lead to unstable product quality, affecting user experience and market competitiveness.

[0006] 4. The adhesives and solvents used in traditional processes will pollute the environment and are not conducive to ecological development. Summary of the invention

[0007] The purpose of the present invention is to solve the shortcomings of the prior art and to propose a fiber integration molding process for surfboards.

[0008] In order to achieve the above object, the present invention adopts the following technical solutions: A fiber integrated molding process for a surfboard comprises the following steps: S1: Select an adjustable modular mold and integrate an electric heating element with a PLC intelligent control system into the mold; S2: Laying the hybrid fiber composite material in the mold; S3: Place an internal pressure bag on the laid prepreg to ensure uniform internal pressure during the molding process; S4: Seal the mold and connect the mold to a vacuum system for vacuum extraction to remove air and volatile substances inside the mold and prevent bubbles from being generated; S5: Place the prepreg into the mold and introduce the resin into the mold. Then use the vacuum system to apply a positive pressure of 6-8 atmospheres inside the inner pressure bag and maintain a vacuum negative pressure in the cavity of the mold to form a composite effect of internal and external positive and negative pressures to ensure that the materials are tightly pressed and residual bubbles are removed. At this time, the mold is heated synchronously through the built-in heating system; S6: After the prepreg is cured, the mold is left to stand at room temperature to slowly cool down to room temperature; S7: Open the mold, take out the formed power surfboard, remove the pressing medium, and perform surface cleaning and quality inspection on the board body; S8: applying a functional coating on the surface of the board; S9: Conduct performance test on finished products.

[0009] Preferably, the mold is an aluminum alloy modular mold, which is composed of a plurality of adjustable modules, and the inner wall of the mold is integrated with electric heating elements to form a built-in heating system.

[0010] Preferably, the hybrid fiber composite material is a carbon fiber prepreg of a fast-curing resin system, and aramid fibers or basalt fibers are added between carbon fiber layers.

[0011] Preferably, the prepreg is laid out in an alternating order of 0° / 90° / ±45°, with a total of 10 layers, and an aramid fiber reinforcement layer is added to the footrest area and tail of the board body.

[0012] Preferably, the inner pressure bag is an inflatable silica gel bag or a high temperature resistant nylon bag.

[0013] Preferably, the resins are introduced into the mold through pipes, and the resins are epoxy resins preheated to 50°C.

[0014] Preferably, when the prepreg is cured, a positive pressure of 0.6-0.7 MPa is applied inside the internal pressure bag, and a vacuum negative pressure is maintained in the cavity of the mold to form an internal and external pressure difference. When the mold is vacuumed, the vacuum system is used to evacuate the mold to (-0.09)-(-0.095) MPa for 15 minutes.

[0015] Preferably, when the prepreg is cured, the temperature in the mold is raised to 80-120° C. by a heating system and kept warm for 1-3 hours.

[0016] Preferably, the coating applied on the surface of the plate body includes anti-slip, self-cleaning, and UV-resistant functional coatings.

[0017] Preferably, the finished product inspection items include ultrasonic flaw detection, mechanical property test, rebound performance test and impact strength test.

[0018] The beneficial effects of the present invention are as follows: by using a modular mold design with a built-in heating system, the prepreg can be used to produce products through integrated molding, and the application of new materials and intelligent control technology are combined, which not only improves the structural strength and production efficiency of the product, but also ensures the quality consistency and environmental protection of the finished product. This process improves the overall performance of the board, simplifies the production process, and reduces costs. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below in combination with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0020] Embodiment 1: A fiber integrated molding process for a surfboard comprises the following steps: S1: Select an adjustable modular mold and integrate an electric heating element with a PLC intelligent control system in the mold to achieve heating and temperature control of the mold itself; S2: Select carbon fiber prepreg with fast curing resin system and add aramid fiber or basalt fiber between carbon fiber layers to form hybrid fiber composite material; S3: Place an inflatable silicone bag or a high temperature resistant nylon bag on the laid prepreg as an internal pressure bag to ensure uniform internal pressure during the molding process; S4: Seal the mold and connect the mold to a vacuum system for vacuum extraction to remove air and volatile substances inside the mold and prevent bubbles from being generated; S5: Place the prepreg into the mold and introduce the resin into the mold. Then use the vacuum system to apply a positive pressure of 6 atmospheres inside the inner pressure bag and maintain a vacuum negative pressure in the cavity of the mold to form a composite effect of internal and external positive and negative pressures to ensure that the materials are tightly pressed and residual bubbles are removed. At this time, the mold is heated synchronously through the built-in heating system; S6: After the prepreg is cured, the mold is left to stand at room temperature to slowly cool down to room temperature; S7: Open the mold, take out the formed power surfboard, remove the pressing medium, and perform surface cleaning and quality inspection on the board body; S8: Apply functional coating on the surface of the board to improve the performance and durability of the product; S9: Perform performance tests on finished products to ensure that product quality meets requirements.

[0021] The mold is an aluminum alloy modular mold, which consists of multiple adjustable modules to adapt to the production of power surfboards of different sizes. The inner wall of the mold is integrated with electric heating elements to form a built-in heating system. By introducing a PLC intelligent control system in the mold, the temperature, pressure, and vacuum degree are monitored and adjusted in real time. The curing curve is set to ensure precise control of the curing process.

[0022] The prepreg material is a carbon fiber prepreg with a fast-curing epoxy resin system. The ply order is 0° / 90° / ±45° alternately arranged, with a total of 10 layers, and aramid fiber reinforcement layers are added to the footrest area and tail of the board. The use of fast-curing resin, bio-based resin and hybrid fiber composite materials improves product performance and meets environmental protection requirements.

[0023] When the mold is vacuumed, the vacuum system is used to evacuate the mold to -0.09MPa for 15 minutes, which can remove air and volatile substances inside the mold and prevent bubbles from forming.

[0024] The resin is introduced into the mold through a pipe, and the resin is preheated to 50°C epoxy resin. In this way, the resin can be evenly impregnated into the fiber layer with the help of vacuum to ensure the density and uniformity of the material.

[0025] When the prepreg is cured, a positive pressure of 0.6MPa is applied inside the mold, and a vacuum negative pressure is maintained in the outer plate cavity of the mold to form an internal and external pressure difference. The curing time is 1h. Ensure that the material is tightly pressed to eliminate residual bubbles.

[0026] When the prepreg is cured, the temperature in the mold is raised to 80°C through the heating system and kept warm for 1 hour. Heating should be carried out according to the preset temperature curve. After curing, it should be slowly cooled to room temperature to prevent deformation or cracking caused by stress concentration in the material.

[0027] Among them, the coatings applied on the surface of the board include anti-slip, self-cleaning, and UV-resistant functional coatings to improve the performance and durability of the product.

[0028] Among them, finished product inspection items include ultrasonic flaw detection, mechanical properties test, rebound performance test and impact strength test, and the test results are guaranteed to meet the standards.

[0029] Embodiment 2: A fiber integrated molding process for a surfboard comprises the following steps: S1: Select an adjustable modular mold and integrate an electric heating element with a PLC intelligent control system in the mold to achieve heating and temperature control of the mold itself; S2: Select carbon fiber prepreg with fast curing resin system and add aramid fiber or basalt fiber between carbon fiber layers to form hybrid fiber composite material; S3: Place an inflatable silicone bag or a high temperature resistant nylon bag on the laid prepreg as an internal pressure bag to ensure uniform internal pressure during the molding process; S4: Seal the mold and connect the mold to a vacuum system for vacuum extraction to remove air and volatile substances inside the mold and prevent bubbles from being generated; S5: Place the prepreg into the mold and introduce the resin into the mold. Then use the vacuum system to apply a positive pressure of 7 atmospheres inside the inner pressure bag and maintain a vacuum negative pressure in the cavity of the mold to form a composite effect of internal and external positive and negative pressures to ensure that the materials are tightly pressed and residual bubbles are removed. At this time, the mold is heated synchronously through the built-in heating system; S6: After the prepreg is cured, the mold is left to stand at room temperature to slowly cool down to room temperature; S7: Open the mold, take out the formed power surfboard, remove the pressing medium, and perform surface cleaning and quality inspection on the board body; S8: Apply functional coating on the surface of the board to improve the performance and durability of the product; S9: Perform performance tests on finished products to ensure that product quality meets requirements.

[0030] The mold is an aluminum alloy modular mold, which consists of multiple adjustable modules to adapt to the production of power surfboards of different sizes. The inner wall of the mold is integrated with electric heating elements to form a built-in heating system. By introducing a PLC intelligent control system in the mold, the temperature, pressure, and vacuum degree are monitored and adjusted in real time. The curing curve is set to ensure precise control of the curing process.

[0031] The prepreg material is a carbon fiber prepreg with a fast-curing epoxy resin system. The ply order is 0° / 90° / ±45° alternately arranged, with a total of 10 layers, and aramid fiber reinforcement layers are added to the footrest area and tail of the board. The use of fast-curing resin, bio-based resin and hybrid fiber composite materials improves product performance and meets environmental protection requirements.

[0032] When the mold is vacuumed, the vacuum system is used to evacuate the mold to -0.0925MPa for 15 minutes, which can remove air and volatile substances inside the mold and prevent bubbles from forming.

[0033] The resin is introduced into the mold through a pipe, and the resin is preheated to 50°C epoxy resin. In this way, the resin can be evenly impregnated into the fiber layer with the help of vacuum to ensure the density and uniformity of the material.

[0034] When the prepreg is cured, a positive pressure of 0.65MPa is applied inside the mold, and a vacuum negative pressure is maintained in the outer plate cavity of the mold to form an internal and external pressure difference. The curing time is 2 hours. Ensure that the material is tightly pressed to eliminate residual bubbles.

[0035] When the prepreg is cured, the temperature in the mold is raised to 100°C through the heating system and kept warm for 2 hours. Heating should be carried out according to the preset temperature curve. After curing, it should be slowly cooled to room temperature to prevent deformation or cracking caused by stress concentration in the material.

[0036] Among them, the coatings applied on the surface of the board include anti-slip, self-cleaning, and UV-resistant functional coatings to improve the performance and durability of the product.

[0037] Among them, finished product inspection items include ultrasonic flaw detection, mechanical properties test, rebound performance test and impact strength test, and the test results are guaranteed to meet the standards.

[0038] Embodiment 3: A fiber integrated molding process for a surfboard comprises the following steps: S1: Select an adjustable modular mold and integrate an electric heating element with a PLC intelligent control system in the mold to achieve heating and temperature control of the mold itself; S2: Select carbon fiber prepreg with fast curing resin system and add aramid fiber or basalt fiber between carbon fiber layers to form hybrid fiber composite material; S3: Place an inflatable silicone bag or a high temperature resistant nylon bag on the laid prepreg as an internal pressure bag to ensure uniform internal pressure during the molding process; S4: Seal the mold and connect the mold to a vacuum system for vacuum extraction to remove air and volatile substances inside the mold and prevent bubbles from being generated; S5: Place the prepreg into the mold and introduce the resin into the mold. Then use the vacuum system to apply a positive pressure of 8 atmospheres inside the inner pressure bag and maintain a vacuum negative pressure in the cavity of the mold to form a composite effect of internal and external positive and negative pressures to ensure that the materials are tightly pressed and residual bubbles are removed. At this time, the mold is heated synchronously through the built-in heating system; S6: After the prepreg is cured, the mold is left to stand at room temperature to slowly cool down to room temperature; S7: Open the mold, take out the formed power surfboard, remove the pressing medium, and perform surface cleaning and quality inspection on the board body; S8: Apply functional coating on the surface of the board to improve the performance and durability of the product; S9: Perform performance tests on finished products to ensure that product quality meets requirements.

[0039] The mold is an aluminum alloy modular mold, which consists of multiple adjustable modules to adapt to the production of power surfboards of different sizes. The inner wall of the mold is integrated with electric heating elements to form a built-in heating system. By introducing a PLC intelligent control system in the mold, the temperature, pressure, and vacuum degree are monitored and adjusted in real time. The curing curve is set to ensure precise control of the curing process.

[0040] The prepreg material is a carbon fiber prepreg with a fast-curing epoxy resin system. The ply order is 0° / 90° / ±45° alternately arranged, with a total of 10 layers, and aramid fiber reinforcement layers are added to the footrest area and tail of the board. The use of fast-curing resin, bio-based resin and hybrid fiber composite materials improves product performance and meets environmental protection requirements.

[0041] When the mold is vacuumed, the vacuum system is used to evacuate the mold to -0.095MPa for 15 minutes, which can remove air and volatile substances inside the mold and prevent bubbles from forming.

[0042] The resin is introduced into the mold through a pipe, and the resin is preheated to 50°C epoxy resin. In this way, the resin can be evenly impregnated into the fiber layer with the help of vacuum to ensure the density and uniformity of the material.

[0043] When the prepreg is cured, a positive pressure of 0.7MPa is applied inside the mold, and a vacuum negative pressure is maintained in the outer plate cavity of the mold to form an internal and external pressure difference. The curing time is 3h. Ensure that the materials are tightly pressed to eliminate residual bubbles.

[0044] When the prepreg is cured, the temperature in the mold is raised to 120°C through the heating system and kept warm for 3 hours. Heating should be carried out according to the preset temperature curve. After curing, it should be slowly cooled to room temperature to prevent deformation or cracking caused by stress concentration in the material.

[0045] Among them, the coatings applied on the surface of the board include anti-slip, self-cleaning, and UV-resistant functional coatings to improve the performance and durability of the product.

[0046] Among them, finished product inspection items include ultrasonic flaw detection, mechanical properties test, rebound performance test and impact strength test, and the test results are guaranteed to meet the standards.

[0047] In this embodiment, the adhesive connection points can be effectively eliminated through the integrated molding fixing process to ensure the integrity of the board structure, thereby significantly improving the strength and durability.

[0048] Furthermore, by adopting fast-curing resin and automated equipment, not only the production cycle is shortened, but also the labor cost is reduced, making it suitable for large-scale production.

[0049] Furthermore, through the intelligent control system, precise control of temperature, pressure and time can be achieved to ensure stable and consistent product quality.

[0050] Furthermore, since this process adopts an integrated molding curing process, the use of adhesives and solvents can be reduced, VOC emissions can be reduced, and the environmental protection effect can be improved.

[0051] Furthermore, through the application of multi-material composites and surface functional coatings, not only the comprehensive performance of the product is improved, but also the diverse needs of users can be met.

[0052] In the present invention, by using a modular mold design with a built-in heating system, the prepreg can be produced through an integrated molding method, and the application of new materials and intelligent control technology are combined, which not only improves the structural strength and production efficiency of the product, but also ensures the quality consistency and environmental protection of the finished product. This process improves the overall performance of the board, simplifies the production process, and reduces costs.

[0053] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A fiber integration molding process for surfboards, characterized in that: The following steps are involved: S1: Select an adjustable modular mold and integrate an electric heating element with a PLC intelligent control system into the mold; S2: Laying the hybrid fiber composite material in the mold; S3: Place an internal pressure bag on the laid prepreg to ensure uniform internal pressure during the molding process; S4: Seal the mold and connect the mold to a vacuum system for vacuum extraction to remove air and volatile substances inside the mold and prevent bubbles from being generated; S5: Place the prepreg into the mold and introduce the resin into the mold. Then use the vacuum system to apply a positive pressure of 6-8 atmospheres inside the inner pressure bag and maintain a vacuum negative pressure in the cavity of the mold to form a composite effect of internal and external positive and negative pressures to ensure that the materials are tightly pressed and residual bubbles are removed. At this time, the mold is heated synchronously through the built-in heating system; S6: After the prepreg is cured, the mold is left to stand at room temperature to slowly cool down to room temperature; S7: Open the mold, take out the formed power surfboard, remove the pressing medium, and perform surface cleaning and quality inspection on the board body; S8: applying a functional coating on the surface of the board; S9: Conduct performance test on finished products.

2. A fiber integrated molding process for surfboards according to claim 1, characterized in that: The mold adopts an aluminum alloy modular mold, which is composed of a plurality of adjustable modules, and the inner wall of the mold is integrated with electric heating elements to form a built-in heating system.

3. The fiber integrated molding process for surfboards according to claim 1, characterized in that: The hybrid fiber composite material is a carbon fiber prepreg of a fast-curing resin system, and aramid fibers or basalt fibers are added between carbon fiber layers.

4. The fiber integration molding process for surfboards according to claim 1, characterized in that: The prepreg is laid in an alternating order of 0° / 90° / ±45°, with a total of 10 layers, and an aramid fiber reinforcement layer is added to the footrest area and the tail of the board.

5. The fiber integrated molding process for surfboards according to claim 1, characterized in that: The inner pressure bag is an inflatable silica gel bag or a high temperature resistant nylon bag.

6. The fiber integration molding process for surfboards according to claim 1, characterized in that: The resins are introduced into the mold through pipes, and the resins are all epoxy resins preheated to 50°C.

7. The fiber integration molding process for surfboards according to claim 1, characterized in that: When the prepreg is cured, a positive pressure of 0.6-0.7MPa is applied inside the internal pressure bag, and a vacuum negative pressure is maintained in the cavity of the mold to form an internal and external pressure difference. When the mold is vacuumed, the vacuum system is used to evacuate the mold to (-0.09)-(-0.095)MPa for 15 minutes.

8. The fiber integration molding process for surfboards according to claim 6, characterized in that: When the prepreg is cured, the temperature in the mold is raised to 80-120° C. by a heating system and kept warm for 1-3 hours.

9. The fiber integration molding process for surfboards according to claim 1, characterized in that: The coatings applied on the surface of the plate body include anti-skid, self-cleaning and anti-ultraviolet functional coatings.

10. The fiber integration molding process for surfboards according to claim 1, characterized in that: The finished product inspection items include ultrasonic flaw detection, mechanical property test, rebound performance test and impact strength test.