A method for forming a composite pattern plate and a tool therefor

Abstract

The application discloses a molding method and tool of a composite material pattern plate in the technical field of composite material manufacturing, and comprises the following steps: S1: selecting an original mold with a target pattern as a basis, and preparing a molding negative mold which is complementary to the target pattern through a first composite material molding process; S2: taking the molding negative mold as a production mold, and preparing a composite material pattern plate with the target pattern through a second composite material molding process, wherein the first composite material molding process and the second composite material molding process are both vacuum introduction processes, and the vacuum introduction process comprises the steps of reinforcing material laying, auxiliary material arrangement, vacuum packaging, vacuumizing, resin injection, curing and demolding. The application adopts an existing stainless steel pattern plate as an original base mold, does not need to separately design and process a customized mold, and the molding negative mold can be repeatedly used, and meanwhile, the vacuum bag packaging tool is combined, so that the time cost and economic investment of mold preparation are greatly reduced, and the production demand of small batches and multiple varieties is adapted.

Description

Technical Field

[0001] This invention relates to the field of composite material manufacturing technology, and more specifically, to a molding method and tooling for a composite material patterned plate with anti-slip / decorative surface pattern prepared by a vacuum induction molding process. Background Technology

[0002] Patterned steel sheets, with their raised patterns, are widely used in various fields such as building decoration, transportation vehicles, machinery and equipment, and shipbuilding due to their attractive appearance, excellent anti-slip properties, and outstanding structural strength. Traditionally, patterned steel sheets are mostly made of metal materials such as aluminum alloy, stainless steel, and ordinary steel. However, as the industrial sector's demands for lightweight, corrosion-resistant, and long-lasting materials continue to increase, the drawbacks of metal patterned steel sheets—such as heavy weight, susceptibility to oxidation and corrosion, and high maintenance costs—have gradually become apparent.

[0003] Glass fiber composite materials have a density that is only about one-third that of steel, but their tensile strength is much higher than that of ordinary steel. They also have excellent corrosion resistance and can remain stable in complex environments such as acids and alkalis, resulting in a significantly extended service life. They are an ideal choice to replace metal materials in the production of patterned plates. Therefore, the development of efficient and reliable composite material patterned plate molding methods has important industrial value.

[0004] Currently, the molding of composite patterned plates mainly relies on customized molds combined with a single molding process. In the existing molding method, customized molds need to be designed and processed separately according to the shape and size of the target pattern. This not only results in long mold manufacturing cycles and high costs, but also poor versatility, making it difficult to adapt to the rapid switching of different pattern types and significantly limiting the production efficiency of small batches and multiple varieties of composite patterned plates.

[0005] Meanwhile, some molding processes suffer from cumbersome operation procedures and high requirements for process details, which can easily lead to problems in actual production. For example, unreasonable design of the flow guiding structure can cause uneven resin impregnation, resulting in incomplete curing, product deformation, and residual air bubbles inside the product. These problems can affect the strength, appearance consistency, and reliability of the composite patterned plate, thus restricting its large-scale promotion and application. On the other hand, molds are indispensable in existing molding methods, increasing production costs. Moreover, some processes are not well compatible with the molds used, leading to product defects, substandard product quality, and material waste, which reduces production stability. In addition, the vacuum introduction process is highly dependent on manual labor, especially in the process of sealing vacuum bags. The vacuum effect and sealing often depend on the skill level of the workers. Therefore, we urgently need a molding method and tooling for composite patterned plates to solve the above problems. Summary of the Invention

[0006] One objective of this invention is to provide a new technical solution for molding composite patterned plates and its tooling. By using a stainless steel patterned plate original mold to create a reusable molding female mold, combined with vacuum bag sealing tooling and standardized vacuum infusion process, the mold manufacturing cost is reduced and the production efficiency is improved. Furthermore, the product has the advantages of being lightweight, high-strength, and corrosion-resistant, making it convenient for subsequent use and promotion.

[0007] The objective of this invention is achieved as follows:

[0008] A method for molding a composite material patterned plate includes the following steps:

[0009] S1: Based on the original mold with the target pattern, a molding female mold complementary to the target pattern is obtained through the first composite material molding process;

[0010] S2: Using the molding female mold as a production mold, a composite material patterned plate with the target pattern is obtained through a second composite material molding process.

[0011] Optionally, in step S1, the original mold is a metal patterned plate.

[0012] Optionally, both the first composite material molding process and the second composite material molding process are vacuum induction processes. The vacuum induction process includes steps such as reinforcing material laying, auxiliary material arrangement, vacuum sealing, vacuuming, resin injection, curing, and demolding. The vacuum induction process also includes a mold pretreatment step, which includes mold cleaning, defect detection, mold release agent coating, and edge sealing treatment of the mold using sealing material.

[0013] Optionally, the reinforcing material is a glass fiber material, including chopped strand mat and multiaxial fabric.

[0014] Optionally, the auxiliary material includes a double-layered vacuum bag, and the vacuuming step uses a vacuuming system with a buffer tank.

[0015] Optionally, the auxiliary material also includes a flow guiding system, which consists of a flow guiding net, a glue injection tube, a glue outlet tube, and a glue injection seat. The glue injection tube is connected to a resin supply device through a transparent, flexible pipe.

[0016] Optionally, the glue injection seat is located at 1 / 3 and 2 / 3 of the axial length of the glue injection tube or glue outlet tube.

[0017] Optionally, the vacuuming step includes first performing a pressure holding leak test, and then continuing to vacuum after the leak test is passed to remove residual air.

[0018] Optionally, the resin is a vinyl resin, and after the resin is injected, a vacuum is maintained until it is completely cured before demolding.

[0019] A tooling used in a method for molding a composite patterned plate includes a flat plate and a sealing frame. Hinges are symmetrically mounted on the flat plate, and the other end of each hinge is connected to the sealing frame. A handle locking nut is rotatably connected to the side of the flat plate away from the hinges. Clamping blocks for fitting the handle locking nuts are symmetrically mounted on the sealing frame. When the sealing frame abuts against the surface of the flat plate, the handle locking nut engages with the corresponding groove on the clamping block to form a locking area. At least two sets of sealing rings for sealing are provided between the flat plate and the sealing frame.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0021] 1. According to an embodiment of the present disclosure, the molding method and tooling of the composite material patterned plate adopts the existing stainless steel patterned plate as the original base mold, without the need for separate design and processing of customized molds, and the molding female mold can be reused repeatedly, which greatly reduces the time cost and economic investment of mold preparation and is suitable for small batch and multi-variety production needs.

[0022] 2. According to an embodiment of this disclosure, the molding method and tooling of the composite material patterned plate uses alkali-free chopped strand mat and four-axis cloth as reinforcing materials, and is fully impregnated and cured with vinyl ester resin through a vacuum infusion process. This gives the product the advantages of being lightweight, with a density only 1 / 3 that of steel, high tensile strength that is much higher than that of ordinary steel, and corrosion resistance. Its service life is significantly better than that of traditional metal patterned plates.

[0023] 3. According to an embodiment of this disclosure, the molding method and tooling of the composite material patterned plate, through the optimization of the arrangement of vacuum auxiliary materials, such as a PE guide net of a specific size, a precisely positioned glue injection seat, simultaneous glue injection through dual glue injection ports, and a process design of 10 minutes of pressure holding and leak detection + 2 hours of continuous vacuuming, effectively avoids defects such as uneven resin impregnation and residual air bubbles inside the product, improves the consistency of product appearance and structural stability, and significantly improves the product qualification rate.

[0024] 4. According to an embodiment of this disclosure, the molding method and tooling of the composite material patterned plate can produce products of different thicknesses as needed by flexibly adjusting the number and thickness of the reinforcing material layers. After demolding, the appearance can be beautified by spray painting. At the same time, the process operation is standardized and the steps are clear, without the need for complex equipment, which takes into account both production flexibility and operation convenience, and expands the application scenarios in multiple fields such as construction, transportation, machinery, and shipbuilding.

[0025] 5. According to one embodiment of the present disclosure, the forming tooling can realize the rapid assembly of vacuum bags, improve production efficiency and save sealing tape, and further reduce the production cost of patterned plates. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0027] Figure 1 This is a flowchart of a molding method for a composite material patterned plate in one embodiment.

[0028] Figure 2 This is a flowchart of the mold pretreatment process for a molding method of a composite material patterned plate in one embodiment.

[0029] Figure 3 This is a first-view schematic diagram of a vacuum bag sealing fixture for a molding method and tooling of a composite material patterned plate in one embodiment.

[0030] Figure 4 This is a second-view schematic diagram of a molding method for a composite material patterned plate and its tooling, as described in one embodiment, illustrating a vacuum bag sealing fixture.

[0031] Figure 5 This is a schematic diagram of the molding method and tooling for a composite material patterned plate in one embodiment, showing the injection process.

[0032] In the diagram: 1. Flat plate; 2. Sealing frame; 3. Hinge; 4. Handle locking nut; 5. Clamping block; 6. Sealing ring; 7. Glue injection seat. Detailed Implementation

[0033] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] like Figure 1-2 As shown, a method for molding a composite material patterned plate includes the following steps:

[0035] S1: Based on the original mold with the target pattern, a molding female mold that complements the target pattern is made through the first composite material molding process.

[0036] In step S1, the original mold is a metal patterned plate.

[0037] Here, the metal patterned plate is made of stainless steel, and its specific size is set at 2500mm×1250mm. This size is suitable for the needs of conventional production scenarios and can ensure the stability of the molding process.

[0038] Furthermore, the selected stainless steel patterned plates must undergo rigorous appearance inspection to ensure that the surface is free of stains, scratches, pits and other defects, and that the overall surface remains clean and flat, so as to avoid affecting the pattern accuracy of the forming die due to defects on the mold surface.

[0039] Furthermore, the stainless steel patterned plate does not require additional pattern processing and can be directly used as a base mold for the preparation of the forming female mold. Its own target pattern structure is the pattern prototype of the subsequent product.

[0040] It is important to note that using existing stainless steel patterned plates as the original mold can eliminate the need for customized mold design and processing, significantly reducing the time and economic costs of mold preparation. Stainless steel is characterized by high strength and high stability, which can accurately replicate the pattern shape, providing a reliable guarantee for the consistency of the pattern in the molding die and the final product.

[0041] S2: Using the molding female mold as a production mold, a composite material patterned plate with the target pattern is obtained through the second composite material molding process.

[0042] Both the first and second composite material molding processes are vacuum induction processes. The vacuum induction process includes steps such as reinforcing material laying, auxiliary material arrangement, vacuum sealing, vacuuming, resin injection, curing, and demolding.

[0043] Here, the first composite material molding process and the second composite material molding process follow the same vacuum induction process logic. Only the key parameters such as the reinforcement material layup and resin dosage are adjusted according to the different molding requirements of the molding die and the final composite material patterned plate to ensure the continuity and compatibility of the two processes.

[0044] Furthermore, each step of the vacuum induction process must be carried out sequentially. The reinforcement material must be laid to completely cover the patterned area of ​​the mold, the auxiliary material layout must be precisely matched with the reinforcement material laying range, and the vacuum sealing must tightly bond the reinforcement material, auxiliary material and mold to form a closed process flow.

[0045] Furthermore, the resin injection operation must be started after the vacuuming reaches the preset process requirements. The curing process must strictly follow the characteristics of the resin and maintain suitable environmental conditions to ensure that the resin is fully cured. The demolding operation must be carried out after the curing is complete to avoid damage to the product due to premature demolding.

[0046] It is important to note that a unified vacuum infusion process is used to prepare the molding die and the final product. This process has a clear logic and strong coherence, making it easy for operators to master and for standardized operations. The steps are connected in an orderly manner and the parameters can be adjusted in a targeted manner, which can effectively reduce the impact of process fluctuations on product quality and significantly improve production stability and product qualification rate.

[0047] The reinforcing materials are glass fiber materials, including chopped strand mat and multiaxial fabrics.

[0048] Here, alkali-free glass fiber is specifically selected as the glass fiber material. The multiaxial fabric is alkali-free four-axis glass fiber fabric, and the chopped strand mat is alkali-free glass fiber chopped strand mat. This type of material has excellent tensile strength and corrosion resistance, which can fully meet the structural performance requirements of the composite patterned plate.

[0049] Furthermore, in the first composite material molding process, the reinforcing material is designed as a four-layer structure, with the layup sequence being chopped strand mat, chopped strand mat, four-axis fabric, and four-axis fabric, with a theoretical thickness of 3mm; in the second composite material molding process, the reinforcing material is designed as a two-layer structure, with the layup sequence being chopped strand mat and four-axis fabric, with a theoretical thickness of 1.5mm, and the thickness of the reinforcing material in the second composite material molding process can be flexibly adjusted according to actual product requirements.

[0050] Furthermore, in both the first and second composite material molding processes, the size of the reinforcing material used is slightly larger than the size of the corresponding mold, ensuring that the patterned area of ​​the mold can be completely covered by the reinforcing material, thus avoiding molding defects caused by blind spots.

[0051] It is important to note that the alkali-free fiberglass reinforcement material has high tensile strength and excellent corrosion resistance, which can significantly improve the structural strength and service life of the composite patterned plate. Different layup structures and thicknesses are designed for different molding requirements of the mold and the product, which not only ensures the structural stability of the molding mold, but also flexibly adapts to the production needs of products with different thicknesses. The reinforcement material is slightly larger than the mold, which can completely cover the patterned area and effectively avoid defects such as material shortage and incomplete pattern due to incomplete coverage.

[0052] The auxiliary materials include a double-layered vacuum bag, and a vacuum system with a buffer tank is used in the vacuuming process.

[0053] Here, the vacuum bag is made of nylon vacuum membrane, and the double-layer structure design can form double protection to avoid the failure of the vacuum environment due to the damage of a single vacuum bag; the buffer tank in the vacuum system is equipped with a pressure gauge to monitor the changes in vacuum level in real time, and the buffer tank is connected between the vacuum pump and the buffer tube to form a complete vacuum circuit.

[0054] Furthermore, when sealing double-layer vacuum bags, the reinforcing materials, auxiliary materials, and molds must be tightly compressed to ensure that there are no loose gaps after sealing. The overall size of the vacuum bag must be compatible with the mold and the laying range of the reinforcing materials to avoid affecting the sealing effect due to improper size. The pressure gauge of the buffer tank must be calibrated in advance to ensure the accuracy of the vacuum monitoring data.

[0055] Furthermore, the core function of the buffer tank is to prevent resin from flowing back to the vacuum pump during the vacuuming process, thus avoiding equipment contamination and damage. At the same time, the real-time feedback from the pressure gauge allows operators to keep track of the operating status of the vacuum system.

[0056] It is worth noting that the double-layer nylon vacuum bag structure significantly reduces the probability of vacuum bag breakage, improves the reliability of vacuum sealing, and reduces process rework caused by vacuum failure; the buffer tank with pressure gauge not only enables real-time monitoring of vacuum level, but also effectively prevents resin backflow, ensuring process stability and extending the service life of vacuum pump.

[0057] To further improve work efficiency, a sealing fixture is used for sealing vacuum bags. When sealing vacuum bags, the forming mold is placed on the sealing fixture plate 1, and the nylon bag film is laid between the sealing frame 2 and the plate 1, and on top of the forming mold. By tightening the handle and locking nut 4, the sealing frame 2 can compress the sealing ring 6 to achieve a sealing effect, thereby avoiding the poor sealing effect that may occur with manual sealing, saving sealing tape, and further reducing costs.

[0058] The auxiliary materials also include a flow guiding system, which consists of a flow guiding net, a glue injection tube, a glue outlet tube, and a glue injection seat 7. The glue injection tube is connected to the resin supply device through a transparent and flexible pipe.

[0059] Here, the flow guiding net of the flow guiding system is made of PE material, the glue injection pipe and the glue outlet pipe are both made of PE flow guiding pipe, and the transparent flexible pipe is made of transparent PU pipe. The resin supplied by the resin supply device is smoothly introduced into the glue injection pipe through the transparent PU pipe to achieve precise delivery of resin.

[0060] The flow guiding system also includes a PE spiral tube, which, together with the PE flow guiding tube and flow guiding net, forms a complete resin flow channel, improving the diffusion efficiency of the resin in the reinforced material and avoiding insufficient local wetting.

[0061] Furthermore, the area of ​​the PE flow guide net must be smaller than the area of ​​the reinforcing material. The PE flow guide net on one side of the injection tube is the same width as the reinforcing material, while the other three sides are reduced by 5cm inward along the edge of the reinforcing material. This design can guide the resin to uniformly wet the reinforcing material. The injection tube and the outlet tube are arranged parallel to each other along the long side of the mold. The injection tube is arranged close to the edge of the reinforcing material, while the outlet tube is 10cm away from the reinforcing material, forming a reasonable resin flow path. Each injection station 7 is equipped with a 1m long transparent PU tube. The PU tube is fixed by a Z-fold and limited by paper tape. When injection needs to be opened, the paper tape can be cut, which is convenient to operate.

[0062] Furthermore, the transparent PU tube not only has the characteristics of being foldable and recyclable, but also allows operators to easily observe the glue injection process and detect abnormalities such as air leaks in a timely manner, providing a direct basis for process adjustments. The matching design of the PE guide tube and the glue injection seat 7 can ensure the smooth delivery of resin and avoid glue blockage problems.

[0063] It is important to note that the PE material flow guiding system components are adapted to the requirements of vacuum infusion process. The size design of the flow guiding net and the arrangement of the flow guiding tube optimize the resin flow path, ensuring that the resin uniformly and quickly impregnates the reinforcing material, thereby improving the injection efficiency and impregnation effect. The transparent PU tube's visualization design facilitates real-time monitoring of the process status, the Z-shaped folding fixing method reduces the risk of air leakage, and the recyclable nature reduces material loss, which is in line with the production concept of energy conservation and consumption reduction.

[0064] The glue injection seat 7 is located at 1 / 3 and 2 / 3 of the axial length of the glue injection tube or glue outlet tube.

[0065] Here, the glue injection seat 7 is made of PE material. Two glue injection seats 7 are set on each glue injection tube and glue outlet tube, located at 1 / 3 and 2 / 3 of the axial length of the tube body, respectively, to realize multi-point introduction and venting of resin.

[0066] Furthermore, the gap between the glue injection seat 7 and the guide tube (glue injection tube or glue outlet tube) needs to be filled with sealing strips to ensure the sealing of the connection and avoid leakage in the vacuum environment or resin seepage.

[0067] Furthermore, after filling the sealing strip, a layer of release cloth needs to be wrapped around the outside of the injection base 7. This design can effectively prevent the injection base 7 from sticking to the vacuum bag film, and facilitate the subsequent demolding operation.

[0068] It is worth noting that the symmetrical distribution design of the injection base 7 on the guide tube enables uniform resin introduction and efficient air discharge, improving the consistency of resin wetting and reducing residual air bubbles inside the product; the combination of sealing strip and release cloth not only ensures the sealing of the vacuum environment, but also avoids the adhesion between the injection base 7 and the vacuum bag, simplifying the demolding process and improving production efficiency.

[0069] The vacuuming process includes first performing a pressure test to check for leaks, and then continuing to evacuate the vacuum after the leak test is passed to remove any residual air.

[0070] Here, the specific operating procedure for pressure holding and leak detection is as follows: after the vacuum is drawn to a stable state, close the air inlet valve of the buffer tank, monitor the change in vacuum degree through the pressure gauge on the buffer tank, and observe whether the vacuum degree remains stable within the preset time.

[0071] Furthermore, the preset monitoring time is set to 10 minutes. If the vacuum level does not decrease within 10 minutes, it is judged as a leak test qualified, indicating that the vacuum sealing system is well sealed. If the vacuum level decreases, the leak point needs to be checked and sealed until the leak test is qualified. After the leak test is qualified, the vacuum state needs to be maintained for 2 hours to ensure that the residual air between the reinforcing material and the mold is completely removed.

[0072] Furthermore, during the continuous vacuuming process, it is necessary to monitor the pressure gauge readings of the buffer tank in real time to maintain a stable vacuum level and avoid affecting the air discharge effect due to vacuum fluctuations.

[0073] It is important to note that the 10-minute pressure holding and leak detection process can accurately determine the airtightness of the vacuum sealing system, promptly detect and address air leaks, and prevent defects such as uneven resin impregnation and internal air bubbles caused by poor sealing from the source. The subsequent 2-hour continuous vacuuming operation can thoroughly remove residual air from the system, significantly improve the density of the composite material, and ensure the structural strength and performance of the product.

[0074] The resin is a vinyl resin. After the resin is injected, a vacuum is maintained until it is fully cured before demolding.

[0075] Here, the vinyl resin can be cured at room temperature without the need for additional heating equipment, simplifying the production process; the resin is injected using a dual-injection-port synchronous start method to ensure that the resin can quickly and evenly cover the reinforcing material.

[0076] Furthermore, a gelation test must be conducted before resin injection. The specific operation method is as follows: weigh at least 3 parts of vinyl resin at the production site, set multiple mixing gradients according to the weight ratio of resin to curing agent 100:(1-3), determine the gelation time suitable for the temperature and humidity conditions at the site through the test, and then select the optimal resin formula; at the same time, the weight ratio of reinforcing material to resin is controlled at 6:4, and the specific amount of resin is calculated and determined according to the weight of reinforcing material and this mixing ratio.

[0077] In this embodiment, in the first composite material molding process, the areal density of the quadriaxial fabric is 1200 g / m2, and the areal density of the chopped strand mat is 225 g / m2. Therefore, the weight of the fiber fabric is 2.5 × 1.25 × (1200 × 2 + 225 × 2) = 8906.3 g, and the amount of resin used is 5937.5 g.

[0078] In the second composite material molding process, the areal density of the quadriaxial fabric is 1200 g / m2, and the areal density of the chopped strand mat is 225 g / m2. Therefore, the weight of the fiber fabric is 2.5 × 1.25 × (1200 + 225) = 4453.1 g, and the amount of resin used is 2968.8 g.

[0079] Furthermore, when the resin flows to the edge of the guide net, stop the injection operation and continue to maintain the vacuum state until the resin is completely cured. After curing, the vacuum state must be maintained for 24 hours before demolding to avoid deformation of the product due to stress release.

[0080] It is important to note that room temperature curing vinyl resins do not require additional heating, reducing production energy consumption and equipment investment costs; the resin formulation determined by gelation tests can be precisely adapted to on-site environmental conditions, ensuring stable resin curing results; simultaneous injection through dual injection nozzles improves injection efficiency, and the 6:4 feed weight ratio balances the structural strength and molding effect of the product; 24 hours of vacuum retention after curing effectively releases internal stress in the product, prevents deformation after demolding, and ensures the dimensional accuracy and pattern integrity of the product.

[0081] The vacuum induction process also includes a mold pretreatment step, which includes mold cleaning, defect detection, application of release agent, and sealing of mold edges with sealing material.

[0082] Here, the mold pretreatment step applies to both the original mold (stainless steel patterned plate) and the forming female mold, ensuring that both types of molds meet the process requirements before use; the selected mold release agent is 770NC, and the sealing material is adhesive release cloth, which is suitable for the use requirements of the vacuum introduction process.

[0083] Furthermore, mold cleaning requires thoroughly removing stains and impurities from the mold surface to avoid affecting the accuracy of pattern replication; defect detection requires carefully checking for scratches, pits, and other problems on the mold surface, and unqualified molds need to be repaired or replaced; the release agent needs to be applied evenly to the mold surface in three coats, and after each coat, it needs to be left to dry completely to ensure the release effect; when sealing the edges, a flat mold 1 with a size larger than the mold to be treated needs to be prepared first, and then the adhesive release cloth is pasted on the edge of the mold to be treated to seal the gap between the mold to be treated and the flat mold 1 to prevent resin leakage.

[0084] It is important to note that the mold pretreatment steps comprehensively ensure the cleanliness, integrity, and sealing of the mold surface, laying a solid foundation for the smooth progress of subsequent processes. After multiple applications and thorough drying, the 770NC release agent forms a uniform release layer, effectively preventing the product from sticking to the mold and simplifying the demolding operation. The edge sealing treatment of the adhesive release cloth, combined with the appropriately sized flat mold, can completely block the resin leakage channels, ensure the stability of the vacuum environment, and reduce material waste and process rework.

[0085] More importantly, the product needs to be inspected after demolding. The inspection items include appearance, hardness and thickness: the appearance must be free of defects, the hardness must be not less than 40HBa, the thickness of the molding female mold obtained by the first composite material molding process must be not less than 3mm±0.2mm, and the thickness of the composite material patterned plate obtained by the second composite material molding process must be not less than 1.5mm±0.2mm. If there are higher requirements for the appearance of the product, it can be painted after passing the inspection to further expand the application scenarios of the product.

[0086] like Figure 3-5 As shown, a tooling used in a method for molding a composite patterned plate is described. The vacuum introduction process employs a vacuum bag sealing tooling to improve the efficiency of assembling vacuum bags. The tooling includes a flat plate 1 and a sealing frame 2. Hinges 3 are symmetrically mounted on the flat plate 1, and the other end of the hinges 3 is connected to the sealing frame 2. A handle locking nut 4 is rotatably connected to the side of the flat plate 1 away from the hinges 3. The sealing frame 2 is symmetrically mounted with locking blocks 5 for fitting the handle locking nuts 4. When the sealing frame 2 abuts against the surface of the flat plate 1, the handle locking nut 4 engages with the corresponding groove on the locking block 5 to form a locking area. At least two sets of sealing rings 6 are provided between the flat plate 1 and the sealing frame 2 for sealing.

[0087] Furthermore, when sealing the vacuum bag, the forming mold is placed on the flat plate 1, and the nylon bag film is laid between the sealing frame 2 and the flat plate 1 and on the forming mold. By tightening the handle and locking nut 4, the sealing frame 2 can squeeze the sealing ring 6 to achieve a sealing effect.

[0088] In this invention, a stainless steel patterned plate with a target pattern is used as the original base mold. First, a sealed and clean molding base is constructed through mold cleaning, defect detection, multiple applications of release agent, and edge sealing with adhesive release cloth. Then, alkali-free glass fiber reinforced material with a size slightly larger than the mold is laid in a preset layering sequence. This is combined with an auxiliary system consisting of nylon release cloth, PE flow guide net (adapted to the reinforcement material according to specific dimensions), flow guide tube with precise positioning injection base 7 (1 / 3, 2 / 3), and transparent PU tube (Z-fold seal). The system is then sealed with a double-layer nylon vacuum bag to form a closed system. The system is first pressure-tested and leak-checked using a vacuum system with a buffer tank. The vacuum is stabilized for 10 minutes, and then vacuumed continuously for 2 hours to completely remove air from the system and avoid residual air bubbles.

[0089] Before resin introduction, the optimal mixing ratio was determined through gelation tests to adapt to the on-site temperature and humidity. The dosage was precisely calculated based on a 6:4 weight ratio of reinforcing material to resin. Simultaneous injection through dual injection ports ensured uniform impregnation. After room temperature curing, vacuum was maintained for 24 hours to offset stress and prevent deformation. Finally, a molded female mold with a pattern complementary to the original mold was obtained through demolding. Because this molded female mold is made of glass fiber composite material, it has both high strength and high toughness and can be reused repeatedly. It can be used as a production mold to repeat the above vacuum introduction process, only adjusting the thickness of the reinforcing material layer and the amount of resin as needed. By utilizing the pattern replication characteristics of the female mold, the resin can be fully impregnated and cured again under vacuum negative pressure, resulting in a lightweight, high-strength, and corrosion-resistant composite material patterned plate. At the same time, through detailed design such as real-time monitoring with transparent PU tubes, optimized flow channels with a flow guiding system, and buffer tanks to prevent resin backflow, a complete process of "pretreatment-layout-encapsulation-vacuuming-injection-curing-demolding" is formed, which not only reduces the cost of customized molds but also achieves standardized and efficient production of products.

[0090] The above description of the embodiments is only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A method for molding a composite material patterned plate, characterized in that: Includes the following steps: S1: Based on the original mold with the target pattern, a molding female mold complementary to the target pattern is obtained through the first composite material molding process; S2: Using the molding female mold as a production mold, a composite material patterned plate with the target pattern is obtained through a second composite material molding process.

2. The molding method of a composite material patterned plate according to claim 1, characterized in that: In step S1, the original mold is a metal patterned plate.

3. The molding method of a composite material patterned plate according to claim 2, characterized in that: Both the first composite material molding process and the second composite material molding process are vacuum induction processes. The vacuum induction process includes steps such as reinforcing material laying, auxiliary material arrangement, vacuum sealing, vacuuming, resin injection, curing, and demolding. The vacuum induction process also includes a mold pretreatment step, which includes mold cleaning, defect detection, mold release agent coating, and edge sealing treatment of the mold using sealing material.

4. The molding method of a composite material patterned plate according to claim 3, characterized in that: The reinforcing material is a glass fiber material, including chopped strand mat and multiaxial fabric.

5. The molding method of a composite material patterned plate according to claim 3, characterized in that: The auxiliary materials include a double-layered vacuum bag, and the vacuuming step uses a vacuuming system with a buffer tank.

6. The molding method of a composite material patterned plate according to claim 3, characterized in that: The auxiliary materials also include a flow guiding system, which consists of a flow guiding net, a glue injection tube, a glue outlet tube, and a glue injection seat. The glue injection tube is connected to the resin supply device through a transparent, flexible pipe.

7. The molding method of a composite material patterned plate according to claim 6, characterized in that: The glue injection seat is located at 1 / 3 and 2 / 3 of the axial length of the glue injection tube or glue outlet tube.

8. The molding method of a composite material patterned plate according to claim 3, characterized in that: The vacuuming step includes first performing a pressure holding leak test, and then continuing to vacuum after the leak test is passed to remove residual air.

9. The molding method of a composite material patterned plate according to claim 3, characterized in that: The resin is a vinyl resin. After the resin is injected, a vacuum is maintained until it is completely cured before demolding.

10. The tooling used in the molding method of a composite material patterned plate according to any one of claims 1-9, characterized in that: The device includes a flat plate and a sealing frame. Hinges are symmetrically mounted on the flat plate, and the other end of each hinge is connected to the sealing frame. A handle locking nut is rotatably connected to the side of the flat plate away from the hinges. The sealing frame has symmetrically mounted locking blocks for fitting the handle locking nuts. When the sealing frame abuts against the surface of the flat plate, the handle locking nut engages with the corresponding groove on the locking block to form a locking area. At least two sets of sealing rings are provided between the flat plate and the sealing frame for sealing.

Images