Instrument box body socket process

Abstract

The invention provides a musical instrument box body socket process which comprises a mold manufacturing stage and a box body blank manufacturing stage, specifically, after a carbon fiber cloth layer is laid and pasted but before a foam core material is laid, a reinforcing agent is evenly scattered on the carbon fiber cloth layer, and the carbon fiber cloth layer and the foam core material are cut to form a socket. According to the musical instrument box body socket process provided by the invention, the carbon fiber cloth layers are combined with the foam core material and the reinforcing agent is added, the reinforcing agent is located between the two carbon fiber cloth layers and partially permeates into the gap of the foam core material, so that the shape, depth and the like of the socket are accurately reserved on the carbon fiber cloth layers with the reinforcing agent; according to the manufacturing process, the strength of the box body is good while the weight of the manufactured box body is light, the thickness and uniformity of the foaming layer can be achieved by adding the reinforcing agent into the gaps of the foam core material, then the strength and durability of the foaming layer are improved, the strength of the inserting opening of the manufactured box body is high, and the process is good in use effect and high in adaptability.

Description

Technical Field

[0001] The present invention relates to the field of musical instrument box packaging manufacturing processes, and particularly to a socket process for musical instrument boxes. Background Art

[0002] In the field of musical instrument manufacturing, the socket process of musical instrument boxes is a key link. Existing foam boxes, wooden boxes, and fiberglass boxes are as follows: foam boxes have an outer cloth bag and a zipper structure at the box mouth, wooden boxes have a relatively thick shell and basically adopt a butting process, and fiberglass boxes use rubber letter strips at the box mouth, that is: For the butting process of wooden boxes: According to the design requirements, multiple wooden boards are spliced through mortise and tenon structures or glue to form the basic framework of the box body. After the basic framework of the box body is made, a socket structure is installed on the framework. The socket is usually made of wood and is formed by carving or splicing, and the entire box body is polished, painted, etc. However, due to the physical properties of wood itself, such as moisture absorption and easy deformation, the socket structure is prone to cracking, deformation, etc. after long-term use. In addition, the density of wood is relatively large, which is not conducive to lightweighting.

[0003] For the rubber letter strip box mouth process of fiberglass boxes: According to the design requirements, the basic shape of the fiberglass box body is made through a mold, and rubber letter strips are installed at the socket position of the box body to provide sealing and buffering functions. After installing the rubber letter strips, the box body is polished, painted, etc.; although fiberglass materials have certain strength and corrosion resistance, the rubber letter strips are prone to aging and falling off after long-term use, resulting in a decrease in the sealing performance of the socket. In addition, the density of fiberglass materials is also relatively large, which is not conducive to lightweighting.

[0004] For the outer cloth bag and zipper structure at the box mouth of foam boxes: According to the design requirements, the basic shape of the foam box body is made, and a zipper structure is installed at the box mouth position. After installation, a cloth bag is wrapped outside it to increase aesthetics and protection; however, the foam material itself has low strength and cannot withstand large loads and impacts. Therefore, the socket structure is prone to deformation, damage, etc. when subjected to external forces. In addition, the zipper structure is also prone to damage after long-term use, affecting the service life of the box body.

[0005] Although these materials have certain strength and stability, they have deficiencies in terms of lightweighting, corrosion resistance, and processing accuracy. With the wide application of carbon fiber composite materials, their excellent mechanical properties and lightweight characteristics provide a new solution for the socket process of musical instrument boxes.

[0006] Carbon fiber composite materials have high strength, high modulus, low density, and good corrosion resistance, and are particularly suitable for making musical instrument box sockets that need to bear large loads and have complex shapes. However, the processing and forming process of carbon fiber composite materials is relatively complex, and precise mold making and curing processes are required to ensure their performance and quality.

[0007] In the current process of musical instrument box sockets, although attempts have been made to use carbon fiber composite materials for production, there are still some problems. For example, in the process flow of musical instrument boxes, the socket structure of the musical instrument box needs to bear large loads and impact forces. However, in the current process of musical instrument box sockets, it is often difficult to ensure the strength and stability of the socket structure, that is, the socket production process often has difficulty achieving a good balance between lightweight and strength, resulting in an overweight or insufficient strength of the overall musical instrument box, and prone to problems such as cracking and deformation.

[0008] Therefore, it is necessary to provide a new process for musical instrument box sockets to solve the above technical problems. Summary of the Invention

[0009] To solve the above technical problems, the present invention provides a process for musical instrument box sockets.

[0010] The process for musical instrument box sockets provided by the present invention includes the following process flow: S1. Mold making stage: a1. Making an aluminum punch and a matching frame for the shell mold: According to the design requirements of the musical instrument box, use machining to make an aluminum punch and an aluminum frame mold matching the aluminum punch, and perform grinding treatment and apply a release agent; a2. Making a carbon fiber shell mold: After the release agent is applied, use carbon fiber prepreg material to layer-by-layer apply on the aluminum punch to make a carbon fiber shell mold. After the application is completed, put the entire mold into a vacuum bag, perform vacuum high-pressure curing. After curing is completed, demold and reserve to obtain a carbon fiber shell mold.

[0011] It should be noted that a specific groove is provided on the aluminum frame mold, and a shell is provided in the groove. When making the product shell 11, a silicone strip with a width of 4 mm and a height of 14 mm will be placed in the groove. The size of the silicone strip exposed from the mold is 10 mm. After curing, removing the silicone strip will form a groove with a width of 4 mm and a depth of 10 mm; Among them, for the specific groove, there is the following understanding: both the inner and outer surfaces of the silicone strip are pasted with carbon cloth, and after curing, removing the silicone strip forms a groove with a width of 4 mm and a depth of 10 mm; It should be further noted that the lower frame mold of the aluminum frame mold has an inward arc angle.

[0012] S2. Box blank making stage: b1. Preparation stage: Cut the carbon fiber prepreg material into the required shape and size in advance, and prepare a foam core material with an appropriate thickness and a reinforcing agent. b2. Laying and curing and shaping: After the preparation stage is completed, apply a release agent to the inner surfaces of the carbon fiber shell mold and the supporting frame, and lay the carbon fiber prepreg layer by layer on the inner surface of the carbon fiber shell mold to form a carbon fiber cloth layer. After laying the carbon fiber cloth layer, but before laying the foam core material, evenly sprinkle the reinforcing agent on the carbon fiber cloth layer. Use a cutting method to precisely reserve the shape and depth of the socket on the carbon fiber cloth layer with the reinforcing agent. Lay the foam core and the carbon fiber cloth layer in sequence on the carbon fiber cloth layer with the reinforcing agent to form a three-layer structure. The reinforcing agent is located between the two carbon fiber cloth layers and partially penetrates into the gaps of the foam core material. Lay a separator film on the uppermost carbon fiber cloth layer, and subject the carbon fiber shell mold and the pre-laid box body to vacuum high-pressure curing. It should be noted that the distance between the foam core material and the edge of the aluminum frame mold is 10 mm. b3. Demolding and trimming: After the mold cools down, take out the box body with the socket after curing is completed, and perform trimming treatment on the box body.

[0013] Preferably, the layer thickness of the carbon fiber cloth layer is 0.1 - 0.5 mm.

[0014] Preferably, the thickness of the foam core material is 1.5 - 2.5 mm.

[0015] Preferably, in the step a1, the edge of the frame mold is in a concave-convex edge shape.

[0016] Preferably, in the step a2, during the process of layer-by-layer application on the aluminum male mold, vacuum pumping treatment is carried out while applying, and the thickness of the applied layer is controlled to be 0.125 mm.

[0017] Preferably, the release agent is an oil-based release agent.

[0018] Preferably, the reinforcing agent is short-cut carbon fiber or glass fiber.

[0019] Preferably, in the step b2, it includes loading the mold and the pre-laid box body into a vacuum bag together, performing vacuum pumping and fixing on the vacuum bag, putting it into a high-temperature curing furnace for heating and curing, and the curing time is 60 - 240 minutes.

[0020] Preferably, in the b3, it also includes that after the mold cools down, the socket structure and the box body blank are integrally formed. Use a file, sandpaper or grinder to trim the socket part, remove the burrs on the edge of the socket and adjust the depth of the socket. After the adjustment is completed, use sandpaper, a grinding machine or a scraper to trim the other parts of the box body.

[0021] Preferably, the steps S1 and S2 further include a secondary curing treatment after the primary curing, and the temperature of the secondary curing is between 150°C and 170°C.

[0022] Compared with the related art, the musical instrument box body socket process provided by the present invention has the following beneficial effects: 1. The present invention adopts a method of combining a carbon fiber cloth layer with a foam core material, and lays a reinforcing agent between the carbon fiber cloth layer and the foam core material. The reinforcing agent is located between the two carbon fiber cloth layers and partially penetrates into the gap of the foam core material, so that the box body is lighter in weight after manufacture and has better strength. The socket manufacturing process can solve the problem of foaming layer thickness and uniformity by adding a reinforcing agent in the gap of the foam core material, thereby improving the strength and durability of the foaming layer, so that the strength of the socket of the box body after manufacture is higher, which solves the problem that it is often difficult to ensure the strength and stability of the socket structure in the current musical instrument box body socket process, so that the produced box body has higher strength; 2. By using carbon fiber composite materials and a specific mold manufacturing process, the present invention effectively solves the problem of insufficient strength and easy cracking and deformation of the socket structure of the traditional musical instrument box. The high strength and high modulus characteristics of carbon fiber composite materials ensure that the socket structure can still maintain good stability and durability when subjected to large loads and impact forces. In addition, carbon fiber composite materials have extremely low density. Compared with traditional materials such as wood and fiberglass, the musical instrument box of the present invention achieves a significant lightweight effect while maintaining high strength and stability. That is, the material is lighter, which is not only easy to carry and transport, but also reduces the extra burden of the musical instrument box on the musical instrument, which helps to protect the safety of the musical instrument. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 A schematic diagram of the overall process of the musical instrument case socket process provided by the present invention; Figure 2 This is a schematic diagram of the process of mold making stage; Figure 3 A schematic cross-sectional structure diagram of the overall musical instrument case socket process provided by the present invention; Figure 4 It is a schematic diagram of the structure of the box body blank; Figure 5 It is a structural diagram of the matching frame.

[0024] Numbers in the figure: 1, box body; 11, ; 2, matching frame; 21, ; 3, socket. DETAILED DESCRIPTION

[0025] The present invention will be further described below in conjunction with the accompanying drawings and implementation modes.

[0026] Please refer to Figures 1 to 5 ,in,Figure 1 Schematic diagram of the overall process of the instrument box socket process provided by the present invention; Figure 3 Schematic diagram of the process in the mold manufacturing stage; Figure 3 Schematic cross-sectional structure diagram of the overall instrument box socket process provided by the present invention; Figure 4 Schematic diagram of the structure of the box blank; Figure 5 Schematic diagram of the structure of the matching frame.

[0027] In the specific implementation process, as Figures 1 to 5 shown, it includes the following technological processes: S1. Mold manufacturing stage: a1. Manufacturing the aluminum punch and the shell mold matching frame 2: According to the design drawings of the instrument box, select high-quality aluminum alloy materials as the raw materials for the punch and the frame, and use a precision numerical control machine tool to process the aluminum punch and the frame to ensure that the shape, size, and precision of the punch meet the design requirements; at the same time, the edge of the frame mold is processed into a concave-convex edge shape, and the processed aluminum punch and frame are carefully polished to remove surface tool marks, burrs and other defects to ensure the surface is smooth and flat. At this time, select a special oil-based mold release agent and evenly apply it on the surface of the aluminum punch and the frame. After the application is completed, wait for the mold release agent to dry thoroughly for the next operation; a2. Manufacturing the carbon fiber shell mold: After the mold release agent is applied, select high-quality carbon fiber prepreg as the mold manufacturing material. When selecting, ensure that the resin content, fiber arrangement, and thickness of the prepreg are uniform. Use the carbon fiber prepreg material to layer-by-layer apply the carbon fiber prepreg on the aluminum punch coated with the mold release agent to manufacture the carbon fiber shell mold. After the application is completed, at this time, put the entire mold into a vacuum bag, including the aluminum punch and the applied carbon fiber layer into the vacuum bag, and perform vacuum high-pressure curing. After the curing is completed, demold and reserve to obtain the carbon fiber shell mold.

[0028] It should be noted that during the application process, vacuum treatment should be carried out while applying to remove the bubbles and excess resin in the prepreg to ensure that each layer of carbon fiber is closely bonded. At the same time, pay attention to controlling the thickness and uniformity of the applied layer; It should be noted that the specific operation steps of curing are as follows: Step1. Preheating stage: First, put the vacuum bag containing the mold into a high-temperature curing furnace, slowly raise the temperature to the lower limit of the preset curing temperature, raise the temperature to 120°C, and maintain it for 30 minutes to preheat the mold and raise the temperature evenly; Step2. Constant temperature curing stage: After the preheating stage is completed, gradually raise the temperature of the curing furnace to the preset curing temperature of 150°C, and maintain a constant time at this temperature to ensure that the resin in the carbon fiber prepreg is completely cured, and the curing time is maintained between 1 and 2 hours; Step 3. Cooling stage: After curing is completed, gradually lower the temperature of the curing furnace to room temperature for secondary curing treatment.

[0029] S2. Box blank manufacturing stage: b1. Preparation stage: According to the design requirements, select appropriate carbon fiber prepreg, foam core material and reinforcing agent, and cut the carbon fiber prepreg material into the required shape and size in advance; b2. Laying and curing and shaping: After the preparation stage is completed, apply a release agent again on the inner surface of the carbon fiber shell mold and the supporting frame 2 to ensure that the box blank can be smoothly demolded during the curing process. Layer by layer, lay the carbon fiber prepreg on the inner surface of the carbon fiber shell mold to form a carbon fiber cloth layer. After laying the carbon fiber cloth layer, but before laying the foam core material, evenly sprinkle the reinforcing agent on the carbon fiber cloth layer. Use cutting to precisely reserve the shape and depth of the socket 3 on the carbon fiber cloth layer with the reinforcing agent. Lay the foam core and another layer of carbon fiber cloth layer in sequence on the carbon fiber cloth layer with the reinforcing agent to form a three-layer structure, ensuring that the foam core is located between the two carbon fiber cloth layers and partially penetrates into the gaps of the foam core material. Lay a separator film on the topmost carbon fiber cloth layer to prevent resin overflow from contaminating the mold during the curing process. Then, put the mold and the pre-laid box 1 into a vacuum bag and perform vacuum fixation. Finally, put the vacuum bag into a high-temperature curing furnace for heating and curing. Among them, the curing process is the same as the curing process in step S1, but in steps S1 and S2, it also includes secondary curing treatment after the primary curing. The temperature of the secondary curing is between 120°C and 180°C; It should be noted that the specific operation steps of the secondary curing are as follows: Stage 1. Primary curing inspection stage: Ensure that the carbon fiber mold or box blank after the primary curing has reached the expected curing degree, the surface is flat and there are no obvious defects. Check and record the parameters such as the temperature, time and pressure in the curing furnace during the primary curing. The temperature of the primary curing is 150°C, and the curing time is between 1 and 2 hours; Stage 2. Cleaning treatment: After the inspection stage is completed, use a clean rag and appropriate cleaning agent to clean the surface of the mold or box blank 1 to remove impurities such as oil stains and dust on the surface. After cleaning, ensure that the surface of the mold or box blank is dry and there is no residual moisture; Stage 3. Preheating and temperature rising: Put the cleaned mold or box blank 1 into a high-temperature curing furnace, slowly raise the temperature to the starting temperature of the secondary curing, which is 120°C, and maintain it for 30 minutes for preheating and uniform temperature rising; Stage Four, Isothermal Curing: After the preheating stage ends, gradually increase the temperature of the curing furnace to the preset secondary curing temperature, which is raised to between 150°C and 170°C. Maintain a constant time at this temperature. When the temperature reaches 160°C, it is the optimal secondary curing temperature to ensure further curing of the resin in the carbon fiber material and improve the performance of the mold and the blank of the box body 1. Among them, the secondary curing time is 80 minutes. Compared with the primary curing, the secondary curing time is shortened, resulting in an increase in the strength of the cured mold. Stage Five, Cooling Stage: After curing is completed, gradually lower the temperature of the curing furnace to room temperature. Among them, the cooling rate needs to be slow to avoid internal stress or deformation of the mold due to too rapid temperature change. After waiting for the mold to cool completely to room temperature, perform demolding treatment.

[0030] It should be noted that the primary curing has already made the resin reach a certain degree of curing. The secondary curing mainly further promotes the complete curing of the resin and improves the overall performance of the material. The shortening of the secondary curing time not only improves production efficiency but also helps to maintain the microstructure of the material, that is, the secondary curing helps to optimize the microstructure of the material, reduce pores and defects, thereby improving the overall performance of the material and avoiding performance degradation that may be caused by long-term high-temperature treatment. At the same time, the shorter curing time also helps to reduce energy consumption and production costs.

[0031] It should be noted that the reinforcing agent can increase the strength and stiffness of the blank of the box body, improve its impact resistance and wear resistance. After laying the reinforcing agent, use a cutting tool to precisely reserve the shape and depth of the socket on the carbon fiber cloth layer with the reinforcing agent.

[0032] b3. Demolding and Trimming: After the mold cools down, the socket 3 structure is integrally formed with the blank of the box body. Use a file, sandpaper or grinder to trim the part of the socket 3, remove the burrs on the edge of the socket 3 and adjust the depth of the socket 3. After the adjustment is completed, use sandpaper, a grinding machine or a scraper to trim the other parts of the box body 1.

[0033] It should be noted that in step a1, the grinding treatment can reduce the friction between the carbon fiber material and the mold during the curing process, avoid surface defects, and applying an oily release agent facilitates subsequent demolding operations, reduces the adhesion between the mold and the carbon fiber material, and protects the mold from damage.

[0034] Reference Figures 1 to 3 As shown, the layer thickness of the carbon fiber cloth layer is 0.1 - 0.5 mm; It should be noted that the layer thickness of the carbon fiber cloth layer is precisely controlled between 0.1 - 0.5 mm. The thinner carbon fiber cloth layer can significantly reduce the weight of the musical instrument box body, making it convenient for carrying and transportation. The high-strength characteristics of carbon fiber can still ensure that the box body 1 has sufficient anti-deformation and anti-fracture capabilities when bearing external forces. Moreover, the thinner cloth layer is more easily adhered to the mold surface, reducing the generation of bubbles and wrinkles, and improving the processing efficiency and quality; The thickness of the foam core material is 1.5 - 2.5 mm; It should be noted that the thickness of the foam core material is 1.5 - 2.5 mm. As the core part of the sandwich structure, the foam core material mainly provides support and heat insulation. And the foam core material has a certain rigidity, which can support the overall structure of the box body 1, preventing deformation during transportation and use. The foam core material also has a certain heat insulation performance, which helps to protect the musical instrument from temperature fluctuations; In step a2, it also includes that during the process of layer-by-layer pasting on the aluminum male mold, vacuum pumping is carried out while pasting, and the thickness of the pasted layer is controlled to be 0.125 mm; It should be noted that when layer-by-layer pasting the carbon fiber cloth layer on the aluminum male mold, the treatment method of vacuum pumping while pasting can ensure that the carbon fiber cloth layer closely adheres to the mold surface during the pasting process, excluding bubbles and excess resin, thereby improving the overall performance and appearance quality of the composite material; at the same time, controlling the thickness of the pasted layer to be 0.125 mm helps to keep the appearance of the box body 1 uniform; The reinforcing agent is chopped carbon fiber or glass fiber. Among them, using chopped carbon fiber or glass fiber as the reinforcing agent can further improve the strength and toughness of the composite material, while maintaining good processability and cost-effectiveness; In step b2, it includes loading the mold and the pre-laid box body into a vacuum bag together, carrying out vacuum pumping and fixing on the vacuum bag, and putting it into a high-temperature curing furnace for heating and curing. The curing time is 60 - 240 minutes.

[0035] The above shows and describes the basic principles, main features and advantages of the present invention. For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or basic features of the present invention. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to include all changes falling within the meaning and scope of the equivalent elements of the claims in the present invention, and any reference signs in the claims should not be regarded as limiting the claimed rights involved.

[0036] In addition, it should be understood that although this specification is described in terms of embodiments, not every embodiment contains only one independent technical solution. This narrative manner of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A musical instrument case socket process, characterized in that: The process includes the following: S1, mold making stage: a1. Making an aluminum convex mold and a matching frame of the shell mold (2): According to the design requirements of the musical instrument case, the aluminum convex mold and the matching aluminum frame mold are made by machining, and then polished and coated with a release agent; a2. Making a carbon fiber shell mold: After the release agent is applied, use carbon fiber prepreg material to apply layer by layer on the aluminum convex mold to make a carbon fiber shell mold. After the application is completed, put the entire mold into a vacuum bag for vacuum high-pressure curing. After the curing is completed, demould it for standby use to obtain a carbon fiber shell mold; S2, box blank production stage: b1. Preparation stage: Cut the carbon fiber prepreg material into the required shape and size in advance, and prepare the foam core material and reinforcing agent of appropriate thickness; b2. Laying and curing: After the preparation stage is completed, a release agent is applied to the inner surface of the carbon fiber shell mold and the matching frame (2), and carbon fiber prepreg is laid layer by layer on the inner surface of the carbon fiber shell mold to form a carbon fiber cloth layer. After laying the carbon fiber cloth layer but before laying the foam core material, a reinforcing agent is evenly spread on the carbon fiber cloth layer, and the shape and depth of the plug (3) are accurately reserved on the carbon fiber cloth layer with the reinforcing agent by cutting. The foam core and the carbon fiber cloth layer are laid in sequence on the carbon fiber cloth layer with the reinforcing agent to form a three-layer structure. The reinforcing agent is located between the two carbon fiber cloth layers and partially penetrates into the gap of the foam core material. An isolation film is laid on the uppermost carbon fiber cloth layer, and the carbon fiber shell mold and the pre-laid box body (1) are vacuumed and high-pressure cured; b3. Demolding and trimming: After the mold is cooled, the box body with the socket is taken out after solidification, and the box body (1) is trimmed.

2. The musical instrument case socket process according to claim 1, characterized in that: The carbon fiber cloth layer has a thickness of 0.1-0.5 mm.

3. The musical instrument case socket process according to claim 2, characterized in that: The thickness of the foam core material is 1.5-2.5 mm.

4. The musical instrument case socket process according to claim 3, characterized in that: In the step a1, the edge of the frame mold (2) is in a concave-convex shape.

5. The musical instrument case socket process according to claim 4, characterized in that: In the step a2, it also includes performing vacuum treatment while laminating on the aluminum male mold layer by layer, and controlling the thickness of the laminating layer to be 0.125 mm.

6. The musical instrument case socket process according to claim 5, characterized in that: The release agent is an oily release agent.

7. The musical instrument case socket process according to claim 6, characterized in that: The reinforcing agent is chopped carbon fiber or glass fiber.

8. The musical instrument case socket process according to claim 7, characterized in that: In the step b2, the mold and the pre-laid box body are placed together in a vacuum bag, and the vacuum bag is evacuated and fixed, and then placed in a high-temperature curing furnace for heating and curing, and the curing time is 60-240 minutes.

9. The musical instrument case socket process according to claim 8, characterized in that: In the above b3, it also includes that after the mold is cooled, the socket (3) structure is integrally formed with the box body blank, and the socket part is trimmed using a file, sandpaper or a grinder to remove burrs on the edge of the socket (3) and adjust the depth of the socket (3). After the adjustment is completed, the other parts of the box body (1) are trimmed using sandpaper, a grinder or a scraper.

10. The musical instrument case socket process according to claim 9, characterized in that: The steps S1 and S2 also include a secondary curing process after the primary curing, and the temperature of the secondary curing is between 150°C and 170°C.

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