Arc-shaped mute wooden door and manufacturing method thereof

Abstract

The application discloses a kind of production methods of arc mute wooden door, comprising the following steps: determining the size of door hole and the arc angle R of door hole, door leaf and keel are processed, according to angle R, upper and lower pressing mould are made by engraver, 3mm straight cutter is used on the back of 5MM wood-plastic door leaf, and several through slots with depth 3mm and length same as panel width are milled, and the whole wood-plastic panel is pressed and bent into arc plate with arc angle R;The keel with arc angle R is milled by engraver, the wood-plastic panel is placed on the lower pressing film made, and several keels are placed in turn, the back panel is attached, the glue is cured by upper pressing film pressing, and the actual demand is cut and trimmed by hand, the arc door panel is made by the way of whole extrusion, mould pressing and milling engraving combination, the construction process of the arc door leaf is simple, the production cost is low, and the arc door panel made will not crack.

Description

Technical Field

[0001] This invention relates to the technical field of curved wooden doors, specifically to a curved silent wooden door and its manufacturing method. Background Technology

[0002] Most wood-plastic composite doors on the market are flat. While flat wood-plastic composite doors can be installed in corner locations, these corners need to be pre-treated to create a flat surface, which is costly. Furthermore, flat wood-plastic composite doors take up significantly more space than curved ones, so curved door panels are required to accommodate these corner installations.

[0003] Currently, the main manufacturing process for wood-plastic composite doors is a one-time extrusion process. This process requires not only a smooth transition in the flow channel design but also a reasonable flow distribution, making the process extremely complex. Furthermore, wood-plastic composite doors produced by this one-time extrusion process are typically flat. The different curvatures between flat and curved panels lead to varying material distribution within the door, placing even greater demands on the mold design. While mold redesign and optimization are possible, the cost is high, and the results are not always ideal. If existing extrusion processes are used, producing curved wood-plastic composite doors in a one-time, one-time extrusion may result in cracking, compromising product quality and wasting raw materials.

[0004] In summary, the current production of curved door panels still faces technical challenges, including complex manufacturing processes that make them prone to cracking and high production costs. Summary of the Invention

[0005] The purpose of this invention is to provide an arc-shaped silent wooden door and its manufacturing method, so as to solve the technical problems of complex manufacturing process, easy cracking and high manufacturing cost of current arc-shaped door panels.

[0006] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution:

[0007] A method for manufacturing an arc-shaped silent wooden door includes the following steps:

[0008] S100. Determine the dimensions and curvature angle R of the doorway: Install the curved base to determine the overall frame of the doorway, and calculate the length and width of the overall frame after it is unfolded into a plane;

[0009] S200, Processing flat door panels and keel: Process flat wood-plastic door panels of the same shape and size as the overall frame after it is unfolded into a flat surface, and process flat keels according to the width of the overall frame after it is unfolded into a flat surface.

[0010] S300, process the curved door leaf and keel; according to the curvature angle R of the door opening, use a carving machine to make the upper and lower pressing molds, and use a straight cutter to mill several through grooves with a depth of 3mm and a length the same as the width of the wood-plastic door leaf on the back of the flat wood-plastic door leaf, and the distance between two adjacent through grooves is 10mm, and the entire flat wood-plastic door leaf is pressed together by the pressing of the upper and lower pressing molds and bent into a curved door leaf with a curvature angle of R;

[0011] According to the arc angle R of the door opening and the thickness of the door leaf, the flat keel is milled into an arc keel using a carving machine; S400, installation of door leaf and keel: Place the curved arc door leaf face down on the prepared pressure film, spray wood glue on the back of the arc door leaf and place several keels in sequence, fix the keel and the arc door leaf with nail guns, and fill the gaps between adjacent keels with reinforcing material. After filling, spray wood glue again and attach the back panel. Use the pressure film to press the glue to cure. The curing time varies from 5 to 8 hours depending on the weather conditions;

[0012] S500, Overall Shaping: The pressed curved door leaf is cut into pieces according to actual needs and then manually sealed at the edges.

[0013] As a preferred embodiment of the present invention, in step S100, the door opening is modified in advance, and a notch is cut on the back of the plywood at a spacing of one centimeter for bending. The radius R is measured to see if it is consistent with the arc base, and the length of the overall frame after unfolding into a plane is determined according to the length of the plywood after it is straightened.

[0014] The two sides of the curved base are leveled with a spirit level and reinforced with expansion screws of 5 cm or more and a nail gun. The gaps are filled with expanding foam to form the basic framework of the entire doorway.

[0015] As a preferred embodiment of the present invention, in step S200, the top plate and the side plate of the door frame are processed according to the size of the door opening and the curvature angle R of the door opening, and the top plate and the side plate of the door frame are both installed on the arc-shaped base in the door opening.

[0016] The top panel of the door frame is milled using a CNC engraving machine according to the thickness of the door leaf and the radius (R-angle). The side panels of the door frame are also milled using a CNC engraving machine according to the height of the door opening.

[0017] After processing, the top and side panels of the door frame are placed in a vacuum forming or wrapping machine for vacuum forming or wrapping, and then cut into shape.

[0018] As a preferred embodiment of the present invention, the door frame side panel has grooves on both sides, the door frame top panel has a door stop groove, the door frame side panel and the door frame top panel are precisely cut and simply connected and placed into the opening, connected with nail gun and fixed with expanding foam.

[0019] After securing it, install the door leaf in the area between the side panel and the top panel of the door frame.

[0020] As a preferred embodiment of the present invention, the spacing between two adjacent keels is ≤7CM, and the number of keels and the spacing between two adjacent keels depend on the height of the door leaf.

[0021] As a preferred embodiment of the present invention, the reinforcing material may be composed of sound-absorbing cotton, door-stop pads, and other materials, and the sound-absorbing cotton and door-stop pads are stacked in a layer-by-layer manner.

[0022] The present invention also provides a wood-plastic door, which is mainly made using a method for manufacturing an arc-shaped silent wooden door, including an arc-shaped door leaf, a door frame top plate and a door frame side plate, wherein a door frame for installing the arc-shaped door leaf is formed between the door frame top plate and the door frame side plate.

[0023] The curved door leaf includes a curved panel and a curved back panel, which are pressed and bonded together. The surface of the panel has several equally spaced through grooves, and several curved keels are installed at equal intervals in the through grooves. A sound-absorbing cotton layer and a door suction pad wooden layer are installed on the panel between two adjacent curved keels in sequence.

[0024] As a preferred embodiment of the present invention, both the sound-absorbing cotton layer and the door-stick pad wooden layer are provided with at least two layers, and the sound-absorbing cotton layer and the door-stick pad wooden layer are alternately provided.

[0025] As a preferred embodiment of the present invention, the adjacent sound-absorbing cotton layers and the door suction pad wooden layers are both bonded and fixed with water-based environmentally friendly adhesive.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] This invention employs a combination of integral extrusion, mold pressing, and milling to produce curved door panels in stages. Flat wood-plastic composite boards, formed by integral extrusion, are pressed into curved wood-plastic doors using molds. The front panel, back panel, and frame of the curved door panel are all independently made from flat wood-plastic composite boards into curved shapes. These components are then pressed together using a mold to achieve the overall production of the curved template. The construction process for producing this curved door is simple, the production cost is low, and the produced curved door panels will not crack. Attached Figure Description

[0028] To more clearly illustrate the embodiments of the present invention or the technical solutions in 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 merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0029] Figure 1 A schematic diagram of the door leaf manufacturing process provided by the present invention;

[0030] Figure 2 This is a schematic diagram of the overall structure of the door leaf provided by the present invention;

[0031] Figure 3 Provided by the present invention Figure 1 A schematic diagram of the structure after the door leaf and door frame are connected;

[0032] Figure 4 Provided by the present invention Figure 2 Top view of the middle door leaf and door frame installed behind the door opening;

[0033] Figure 5 A process diagram illustrating the pressing of a straight panel into an arc-shaped panel, provided by this invention;

[0034] Figure 6 A process diagram illustrating the assembly of the arc-shaped panel, arc-shaped keel, and arc-shaped back plate provided by this invention;

[0035] The labels in the diagram represent the following:

[0036] 1. Curved door leaf; 2. Door frame top panel; 3. Door frame side panel;

[0037] 11. Curved panel; 12. Curved back panel; 13. Through groove; 14. Curved keel; 15. Sound-absorbing cotton layer; 16. Door suction pad wooden layer. Detailed Implementation

[0038] 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.

[0039] A method for manufacturing an arc-shaped silent wooden door, such as... Figure 1 As shown, it includes the following steps:

[0040] S100. Determine the dimensions and curvature angle R of the door opening: Install the curved base to determine the overall frame of the door opening, and calculate the length and width of the overall frame after it is unfolded into a plane, wherein the width of the overall frame after it is unfolded into a plane is the same as the height of the door opening.

[0041] S200, Processing flat door panels and keel: Process wood-plastic door panels of the same shape and size as the overall frame after it is unfolded into a flat surface; process flat keels according to the width of the overall frame after it is unfolded into a flat surface.

[0042] S300, process the curved door leaf and keel; according to the curvature angle R of the door opening, use a carving machine to make the upper and lower pressing molds, and use a straight cutter to mill several through grooves with a depth of 3mm and a length the same as the width of the wood-plastic door leaf on the back of the flat wood-plastic door leaf, and the distance between two adjacent through grooves is 10mm, and the entire flat wood-plastic door leaf is pressed together by the pressing of the upper and lower pressing molds and bent into a curved door leaf with a curvature angle of R;

[0043] Based on the arc angle R of the door opening and the thickness of the door leaf, the flat keel is milled into an arc keel using a carving machine;

[0044] S400, Installation of door leaf and keel: Place the curved door leaf face down on the prepared pressure film, spray wood glue on the back of the curved door leaf and place several keels in sequence, fix the keels to the curved door leaf with nail guns, and fill the gaps between adjacent keels with reinforcing material. After filling, spray wood glue again and attach the back panel. Use the pressure film to press the glue to cure. The curing time varies from 5 to 8 hours depending on the weather.

[0045] S500, Overall Shaping: The pressed curved door leaf is cut into pieces according to actual needs and then manually sealed at the edges.

[0046] The back of the 5mm wood-plastic composite panel is milled with a 3mm straight cutter, and several through slots with a depth of 3mm and a length equal to the width of the panel. The through slots can reduce the thickness of the panel, thereby improving the overall ductility of the panel. Under the pressure of the mold, it can quickly bend and deform, and the bending process will not affect the overall reduction of the panel, nor will it cause the panel to bend and crack.

[0047] Since most door panels made using co-extrusion are straight boards, conventional co-extrusion technology cannot meet the requirements for making curved door panels, or more complex processes are needed, which would greatly increase the production cost of curved door panels. This invention uses a combination of integral extrusion, mold pressing, and milling to produce curved door panels in stages. The planar wood-plastic composite board, which is integrally extruded, is pressed into a curved wood-plastic door using a mold. The front panel, back panel, and keel of the curved door panel are all made of planar wood-plastic composite board in an independently curved shape. The prepared front panel, back panel, and keel are then pressed together using a mold to achieve the integral production of the curved template. The construction process for making this curved door panel is simple, the production cost is low, and the produced curved door panel will not crack. Furthermore, the important parts of the wood-plastic door are reinforced with keels to ensure the overall installation quality and structural strength.

[0048] The door panel and the keel are both made of flat wood-plastic composite board using an integral extrusion process. Since the thickness of the keel is much greater than the thickness of the door panel back panel and the length of the keel is relatively short, the keel is prone to breakage when it is integrally pressed and bent. To avoid this phenomenon, the door panel can be made using a pressing process, while the keel can be made by milling out the keel with a bending angle of R using a carving machine.

[0049] The size of the door leaf mainly depends on the size of the door opening. Before the door opening is reserved in an arc shape, it needs to be modified to meet the installation requirements of the manufactured door leaf.

[0050] Specifically, such as Figure 4 As shown, in step S100, the door opening is modified in advance. A notch is cut on the back of the plywood at a spacing of one centimeter for bending. The radius R is measured to see if it is consistent with the arc base. The length of the overall frame after unfolding into a plane is determined according to the length of the plywood after it is straightened.

[0051] The two sides of the curved base are leveled with a spirit level and reinforced with expansion screws of 5 cm or more and a nail gun. The gaps are filled with expanding foam to form the basic framework of the entire doorway.

[0052] The curved base layer ensures that the curvature angle R of the door opening is the same as that of the door leaf, so that the door leaf can be accurately installed in the door opening later.

[0053] Since the installation of the door leaf also requires the cooperation of the door frame, it can not only increase the overall aesthetics, but also facilitate the installation of the entire door leaf.

[0054] Specifically, such as Figure 3 As shown, in step S200, the top plate and side plate of the door frame are processed according to the size of the door opening and the curvature angle R of the door opening. The top plate and side plate of the door frame are both installed on the curved base in the door opening.

[0055] The top panel of the door frame is milled using a CNC engraving machine according to the thickness of the door leaf and the radius (R-angle). The side panels of the door frame are also milled using a CNC engraving machine according to the height of the door opening.

[0056] After processing, the top and side panels of the door frame are placed in a vacuum forming or wrapping machine for vacuum forming or wrapping, and then cut into shape.

[0057] The top panel of the door frame is made of 12mm wood-plastic composite board milled into a shape with an arc angle of R, and the side panel of the door frame is made of 15mm wood-plastic composite board + 12mm LVL composite material. The matching installation of the top panel and the side panel of the door frame can block the door leaf, ensuring that the door leaf can be closed at a specific position in the doorway and can only open and close in one direction.

[0058] Since the top and side panels of the door frame occupy part of the door opening space, the dimensions of the top and side panels of the door frame need to be taken into account when shaping the overall curved door panel so that the curved door panel can be accurately installed in the door opening of the corresponding size.

[0059] Furthermore, the door frame side panels have grooves on both sides, and the door frame top panel has a door stop groove. The door frame side panels and the door frame top panel are precisely cut and simply connected to be inserted into the opening. They are then connected with nail guns and filled with expanding foam for fixation.

[0060] After securing it, install the door leaf in the area between the side panel and the top panel of the door frame.

[0061] The double-sided grooves on the side panels of the door frame are mainly used to limit the movement of the door leaf side walls, while the door stop groove on the top panel of the door frame is used to limit the movement of the top of the door leaf.

[0062] When manufacturing door panels, the main technology used is straight-plate compression molding. The main support strength of the door panel is provided by the keel. The number of keels determines the strength of the entire door panel. Appropriate keel technology can improve the overall strength and also save materials.

[0063] Specifically, the spacing between two adjacent keels is ≤7CM. The number of keels and the spacing between two adjacent keels depend on the height of the door. The outer frame material of the keel is 18 wood-plastic board + 24LVL composite panel. The composite keel has the advantages of high plasticity, waterproof and flame retardant properties.

[0064] The spacing should ideally be a common divisor of the door leaf lengths to ensure that the spacing between each joist is the same.

[0065] This invention provides an arc-shaped silent wood-plastic door, mainly utilizing a method for manufacturing arc-shaped silent wood doors, such as... Figure 2-6 As shown, it includes an arched door leaf 1, a door frame top plate 2 and a door frame side plate 3, and a door frame for installing the arched door leaf 1 is formed between the door frame top plate 2 and the door frame side plate 3.

[0066] The curved door leaf 1 includes a curved panel 11 and a curved back panel 12. The curved panel 11 and the curved back panel 12 are pressed and bonded together. Several equally spaced through grooves 13 are opened on the surface of the panel. Several curved keels 14 are installed at equal intervals in the through grooves 13. A sound-absorbing cotton layer 15 and a door suction pad wooden layer 16 are installed on the panel between two adjacent curved keels 14 in sequence.

[0067] This curved door not only has a curved shape, but also has high overall strength, making it suitable for installation in places with corners.

[0068] Specifically, such as Figure 2As shown, both the sound-absorbing cotton layer 15 and the door-suction pad wooden layer 16 are provided with at least two layers, and the sound-absorbing cotton layer 15 and the door-suction pad wooden layer 16 are alternately provided. The height of the alternately provided layers needs to be slightly higher than the thickness of the door leaf. This is mainly because they need to be pressed together later, and there may be compression deformation between the sound-absorbing cotton layer 15 and the door-suction pad wooden layer 16. As long as the final pressed thickness is the same as the thickness of the door opening, it is acceptable.

[0069] The multi-layered design provides excellent noise reduction and also enhances overall strength.

[0070] Furthermore, such as Figure 2 As shown, the adjacent sound-absorbing cotton layer 15 and the door suction pad wooden layer 16 are glued and fixed with water-based environmentally friendly adhesive, which facilitates a firm connection between the sound-absorbing cotton layer 15 and the door suction pad wooden layer 16.

[0071] The above embodiments are merely exemplary embodiments of this application and are not intended to limit this application. The scope of protection of this application is defined by the claims. Those skilled in the art can make various modifications or equivalent substitutions to this application within its substance and scope of protection, and such modifications or equivalent substitutions should also be considered to fall within the scope of protection of this application.

Claims

1. A method for manufacturing an arc-shaped silent wooden door, characterized in that, Includes the following steps: S100. Determine the dimensions and curvature angle R of the doorway: Install the curved base to determine the overall frame of the doorway, and calculate the length and width of the overall frame after it is unfolded into a plane; S200, Processing flat door panels and keel: Process flat wood-plastic door panels of the same shape and size as the overall frame after it is unfolded into a flat surface, and process flat keels according to the width of the overall frame after it is unfolded into a flat surface. S300, Processing curved door panels and keel; According to the curvature angle R of the door opening, use a carving machine to make an upper and lower pressing mold. Use a straight cutter to mill several through grooves with a depth of 3mm and a length the same as the width of the wood-plastic door panel on the back of the flat wood-plastic door panel, and the distance between two adjacent through grooves is 10mm. Under the pressure of the upper and lower pressing molds, the entire flat wood-plastic door panel is pressed and bent into a curved door panel with a curvature angle of R. Based on the arc angle R of the door opening and the thickness of the door leaf, the flat keel is milled into an arc keel using a carving machine; S400 Installation of curved door leaf and keel: Place the curved door leaf face down on the prepared pressure film, spray wood glue on the back of the curved door leaf and place several keels in sequence. Fix the keels to the curved door leaf with nail guns and fill the gaps between adjacent keels with reinforcing material. After filling, spray wood glue again and attach the back panel. Use the pressure film to press the glue to cure. The curing time varies from 5 to 8 hours depending on the weather. S500, Overall Shaping: The pressed curved door leaf is cut into precise pieces according to actual needs and the edges are sealed by hand; In step S100, the door opening is modified in advance. A notch is cut on the back of the plywood at a spacing of one centimeter for bending. The radius R is measured to see if it is consistent with the arc base. The length of the overall frame after unfolding into a plane is determined based on the length of the plywood after it is straightened. The two sides of the curved base are leveled with a spirit level and reinforced with expansion screws of 5 cm or more and a nail gun. The gaps are filled with expanding foam to form the basic framework of the entire doorway. The reinforcement material consists of sound-absorbing cotton and door-stop pads, which are stacked in layers.

2. The method for manufacturing an arc-shaped silent wooden door according to claim 1, characterized in that, In step S200, the top panel and side panel of the door frame are processed according to the size and dimensions of the overall frame. Both the top panel and side panel of the door frame are installed on the arc-shaped base in the door opening. The top panel of the door frame is milled using a CNC engraving machine according to the thickness of the door leaf and the radius (R-angle). The side panels of the door frame are also milled using a CNC engraving machine according to the height of the door opening. After processing, the top and side panels of the door frame are placed in a vacuum forming or wrapping machine for vacuum forming or wrapping, and then cut into shape.

3. The method for manufacturing an arc-shaped silent wooden door according to claim 2, characterized in that, The door frame side panel has grooves on both sides, and the door frame top panel has a door stop groove. The door frame side panel and the door frame top panel are precisely cut and simply connected to be inserted into the opening. They are then connected with nail guns and filled with expanding foam for fixation. After securing it, install the door leaf in the area between the side panel and the top panel of the door frame.

4. The method for manufacturing an arc-shaped silent wooden door according to claim 1, characterized in that, The spacing between two adjacent keels is ≤7CM. The number of keels and the spacing between two adjacent keels depend on the height of the door.

5. The curved silent wooden door manufactured according to any one of claims 1-4, characterized in that, It includes an arc-shaped door leaf (1), a door frame top plate (2) and a door frame side plate (3), and a door frame for the arc-shaped door leaf (1) is formed between the door frame top plate (2) and the door frame side plate (3); The curved door leaf (1) includes a curved panel (11) and a curved back panel (12). The curved panel (11) and the curved back panel (12) are pressed and bonded together. Several equally spaced through grooves (13) are opened on the surface of the curved panel (11). Several curved keels (14) are installed at equal intervals in the through grooves (13). A sound-absorbing cotton layer (15) and a door suction pad wood layer (16) are installed on the curved panel (11) between two adjacent curved keels (14).

6. The curved silent wooden door according to claim 5, characterized in that, The sound-absorbing cotton layer (15) and the door suction pad wooden layer (16) are each provided with at least two layers, and the sound-absorbing cotton layer (15) and the door suction pad wooden layer (16) are provided alternately.

7. The curved silent wooden door according to claim 6, characterized in that, The adjacent sound-absorbing cotton layer (15) and the door suction pad wood layer (16) are glued and fixed together with water-based environmentally friendly adhesive.

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