Anti-corrosion wooden door and manufacturing method thereof

Abstract

The invention discloses an anti-corrosion wooden door and a manufacturing method thereof. The anti-corrosion wooden door comprises an anti-corrosion layer and a strengthening structure layer which are sequentially arranged in a stacked mode. The anti-corrosion layer is the outer layer of the anti-corrosion wooden door, the strengthening structure layer is the inner layer of the anti-corrosion wooden door, and the anti-corrosion layer and the strengthening structure layer are combined. Through the double-layer structural design, an effective anti-corrosion barrier can be formed, and the anti-corrosion performance of the wooden door is greatly improved; high-performance materials such as HDPE and stainless steel fiber composite materials and phenolic resin impregnated paper laminated boards are adopted, and it is guaranteed that the wooden door has excellent damp-proof and anti-corrosion performance; the anti-corrosion capacity of the wooden door is further improved through the processes of surface anti-corrosion paint coating, metal part galvanization or stainless steel surface treatment, gap sealing treatment and the like.

Description

Technical Field

[0001] The invention relates to the technical field of anti-corrosion wooden doors, and in particular to an anti-corrosion wooden door and a manufacturing method thereof. Background Art

[0002] In specific usage environments, especially places with high humidity and the presence of corrosive gases or substances, the anti-corrosion performance of existing wooden doors is particularly insufficient, which directly affects the durability and service life of the wooden doors and may even pose a potential threat to human health.

[0003] Specifically, traditional wooden doors are made of solid wood or solid wood composite panels. Their materials and structures make them easy to absorb moisture and corrosive substances. If traditional wooden doors are exposed to humid or corrosive environments for a long time, they are prone to decay, discoloration and strength loss. Furthermore, areas with high humidity such as bathrooms, kitchens, basements, and places with corrosive gases such as the seaside and chemical plants place higher requirements on the corrosion resistance of wooden doors. In these environments, the corrosion resistance of existing wooden doors often cannot meet the needs of long-term use. In addition, temperature changes will also affect the performance of wooden doors. Especially under extreme temperature differences, the moisture content inside the wood will change dramatically, causing the wood to expand and shrink, accelerating the corrosion process. Since wooden doors are long-term used items, once they are severely corroded, their strength and stability will be seriously affected, and they may not be able to effectively perform the functions of separating spaces and protecting privacy. They may even fail to open smoothly in an emergency, posing a safety hazard. Summary of the invention

[0004] The object of the present invention is to provide an anti-corrosion wooden door and a manufacturing method thereof, thereby solving all or one of the above-mentioned problems existing in the prior art.

[0005] In order to solve the above technical problems, the specific technical solutions of the present invention are as follows: In one aspect, the present invention provides an anti-corrosion wooden door, comprising: The anti-corrosion layer and the strengthening structure layer are stacked in sequence; the anti-corrosion layer is the outer layer of the anti-corrosion wooden door, the strengthening structure layer is the inner layer of the anti-corrosion wooden door, and the anti-corrosion layer and the strengthening structure layer are combined with each other.

[0006] As an improved solution, the anti-corrosion layer is made of a composite material of high-density polyethylene and stainless steel fibers; The mass proportion of the high-density polyethylene is 80%-90%; The mass proportion of the stainless steel fiber composite material is 10%-20%.

[0007] As an improved solution, the reinforcing structural layer comprises: a phenolic resin impregnated paper laminate; the phenolic resin impregnated paper laminate is made of wood fiber, phenolic resin and flame retardant; The mass proportion of the wood fiber is 70%-90%; The mass proportion of the phenolic resin is 8%-25%; The mass proportion of the flame retardant is 2%-5%.

[0008] On the other hand, the present invention also provides a method for manufacturing an anti-corrosion wooden door, comprising the following steps: Make anti-corrosion layer and strengthen structural layer; Laminating and assembling the anti-corrosion layer and the strengthening structure layer to obtain a first preliminary door panel; Performing fine anti-corrosion treatment on the first preliminary door panel to obtain a second preliminary door panel; Anti-corrosion paint is applied several times on the surface of the second preliminary door panel and the door frame to obtain a finished anti-corrosion wooden door.

[0009] As an improved solution, the preparation of the anti-corrosion layer and the strengthening structure layer includes: The stainless steel fibers are evenly dispersed in the molten HDPE, and a composite material is made through an extrusion molding process to obtain a preliminary anti-corrosion layer.

[0010] As an improved solution, the manufacturing of the anti-corrosion layer and the strengthening structure layer further includes: The surface of the preliminary anti-corrosion layer is coated with a special anti-corrosion coating to obtain the anti-corrosion layer.

[0011] The special anti-corrosion coating comprises: a composite coating with epoxy resin as base material and anti-corrosion pigment and additives added therein.

[0012] As an improved solution, the process of making the anti-corrosion layer and the strengthening structure layer further includes: After the wood fibers are dried and screened, they are impregnated with phenolic resin and cured under high temperature and high pressure to obtain a laminate with moisture-proof and corrosion-resistant properties, and the laminate is used as the reinforcing structural layer.

[0013] As an improved solution, the anti-corrosion layer and the strengthening structure layer are laminated and assembled to obtain a first preliminary door panel, comprising: Cutting and splicing the strengthening structure layer to obtain a basic door leaf frame; A layer of anti-corrosion glue is evenly coated on the surface of the door leaf basic frame, and then the anti-corrosion layer is attached to the door leaf basic frame, and the anti-corrosion layer and the door leaf basic frame are tightly combined by a hot pressing process to obtain the first preliminary door panel; The anti-corrosion glue includes: polyurethane glue.

[0014] As an improved solution, the first preliminary door panel is subjected to a refined anti-corrosion treatment to obtain a second preliminary door panel, comprising: The metal parts to be installed on the first preliminary door panel are all subjected to galvanizing or stainless steel surface treatment; The first preliminary door panel is cut and punched, the galvanized or stainless steel surface-treated metal component to be installed is installed at the installation position, and the surface of the first preliminary door panel is polished to obtain the second preliminary door panel.

[0015] As an improved solution, the anti-corrosion coating is made of 12 parts of water-based resin, 8 parts of polydimethylsiloxane, 1.5 parts of mica powder, 5 parts of silicone-modified styrene acrylic emulsion, 2 parts of sodium polyphosphate and wetting dispersant, 8 parts of bactericide, 5 parts of pH regulator, 6.5 parts of film-forming aid and 4.5 parts of stabilizer.

[0016] The beneficial effects of the technical solution of the present invention are: The present invention forms an effective anti-corrosion barrier through a double-layer structural design, thereby greatly improving the anti-corrosion performance of wooden doors; adopts high-performance materials such as HDPE and stainless steel fiber composite materials, phenolic resin impregnated paper laminates, etc., to ensure that the wooden doors have excellent moisture-proof and corrosion-resistant properties; through surface anti-corrosion paint coating, galvanizing of metal parts or stainless steel surface treatment, gap sealing treatment and other processes, the corrosion resistance of wooden doors is further improved, and it is suitable for various corrosion-prone environments, effectively solving the problems of easy corrosion and deformation of traditional wooden doors in harsh environments such as humidity and salt spray. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 is a schematic diagram of the cross-sectional structure of the anti-corrosion wooden door described in Example 1 of the present invention when viewed from a side perspective; Figure 2 It is a schematic flow chart of the method for manufacturing the anti-corrosion wooden door according to Embodiment 1 of the present invention; The symbols in the accompanying drawings are explained as follows: 1. Anti-corrosion layer; 2. Strengthening structural layer. DETAILED DESCRIPTION

[0019] The preferred embodiments of the present invention are described in detail below in conjunction with the accompanying drawings so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more definite definition of the protection scope of the present invention.

[0020] In the description of the present invention, it should be noted that the embodiments described in the present invention are only part of the embodiments of the present invention, rather than all of the embodiments; based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0021] The terms "first", "second", etc. in the specification and claims of this article and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged where appropriate, so that the embodiments of this article described here can be implemented in an order other than those illustrated or described here. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions, for example, a process, method, device, product or equipment that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or equipment.

[0022] Embodiment 1, this embodiment provides an anti-corrosion wooden door, such as Figure 1 As shown, it includes: an anti-corrosion layer and a strengthening structure layer stacked in sequence; Specifically, the outer layer of the anti-corrosion wooden door is an anti-corrosion layer, and the inner layer is a reinforced structural layer. The two layers are tightly combined through a special process to form an effective anti-corrosion barrier; Specifically, the anti-corrosion layer includes: a high-density polyethylene (HDPE) and stainless steel fiber composite material; Among them, the weight ratio of high-density polyethylene (HDPE) and stainless steel fiber composite material is HDPE 80%-90%, stainless steel fiber composite material 10%-20%; Specifically, the strengthening structure layer includes: phenolic resin impregnated paper laminate; Among them, the phenolic resin impregnated paper laminate is made of wood fiber, phenolic resin and flame retardant, and the weight ratio of these components is 70%-90% of wood fiber, 8%-25% of phenolic resin and 2%-5% of flame retardant.

[0023] In addition, in order to verify the anti-corrosion performance of the wooden door of this application, a comparative experiment of various indicators of the anti-corrosion wooden door and the traditional wooden door was conducted. The test items include but are not limited to key indicators such as anti-corrosion performance, moisture content, immersion peeling performance, surface bonding strength, weather resistance and formaldehyde emission. The test follows the relevant industry standards and uses professional testing equipment and scientific methods. The specific test results are as follows: project Anti-corrosion wooden door Traditional wooden door in conclusion Anti-corrosion properties ≥95.85% (Excellent) ≤70% (generally) The anti-corrosion wooden door of this application has been specially treated and has excellent anti-corrosion performance, effectively resisting corrosive environments such as moisture, acid and alkali. Moisture content ≤10% (ideal range) 12%-15% (high) The anti-corrosion wooden door of this application strictly controls the moisture content, maintains dimensional stability, and reduces the risk of deformation and cracking. Dip stripping performance No obvious peeling Slight peeling The anti-corrosion wooden door of the present application has excellent gluing performance and can maintain structural stability even in a humid environment. Surface bonding strength ≥0.6MPa (high strength) ≤0.4MPa (general) The anti-corrosion wooden door of the present application has higher surface bonding strength, stronger durability and is not easy to be damaged. Weather resistance Excellent (withstands extreme weather conditions) Average (subject to weather conditions) The anti-corrosion wooden door of the present application has excellent weather resistance and can maintain stable performance under adverse weather conditions. Fire performance Flame retardant B1 grade (excellent) Flammable (general) The anti-corrosion wooden door of the present application has been specially treated to have high fire resistance and improve home safety. Formaldehyde emission ≤0.5mg / L (very low) ≤1.5mg / L (national standard) The anti-corrosion wooden door of this application strictly controls the formaldehyde emission, ensures the indoor air quality, and protects the health of the family. It should be noted that the examples herein are only for explaining the present invention and are not intended to limit the protection scope of the present invention.

[0024] Embodiment 2, this embodiment is based on the same inventive concept as the anti-corrosion wooden door described in Embodiment 1, and provides a method for manufacturing an anti-corrosion wooden door, such as Figure 2 As shown, the following steps are included: S100, making anti-corrosion layer: S101, melted HDPE; uniformly dispersing the stainless steel fibers in the melted HDPE, and making a composite material through an extrusion molding process, the material having excellent corrosion resistance, wear resistance and strength, to obtain a preliminary anti-corrosion layer; S102. The surface of the preliminary anti-corrosion layer is coated with a special anti-corrosion coating to further improve the anti-corrosion performance. The special anti-corrosion coating is based on epoxy resin and is added with anti-corrosion pigments and additives to form a dense anti-corrosion coating to further improve the anti-corrosion performance.

[0025] S200, making a reinforced structural layer: S201. After drying and screening, the wood fibers are impregnated with phenolic resin and cured under high temperature and high pressure to form a laminate with excellent moisture and corrosion resistance as a reinforcing structural layer.

[0026] S300, lamination assembly: S301, firstly cutting and splicing the strengthening structure layer according to the design requirements to form the basic frame of the door leaf; S302, then evenly coating a layer of anti-corrosion glue on the surface of the basic frame, and then laminating the anti-corrosion layer material thereon, and combining them tightly through a hot pressing process to obtain a first preliminary door panel; the anti-corrosion glue can be polyurethane glue.

[0027] S400, refined processing: S401. All metal parts required on wooden doors (such as door locks, hinges, etc.) are galvanized or stainless steel surface treated to enhance their corrosion resistance; S402, performing fine cutting and punching on the first preliminary door panel, installing anti-corrosion treated door locks, hinges and other hardware accessories at required positions according to specific needs, and performing surface polishing to obtain a second preliminary door panel.

[0028] S500, apply anti-corrosion paint on the surface of the second preliminary door panel and the door frame, and apply it multiple times, wait for the door panel to air dry after each application, and continue to apply it after air drying; the number of applications is determined according to the anti-corrosion requirements, and can be 2 times, 3 times or 5 times, etc., to ensure that the coating is uniform and dense, and the final anti-corrosion wooden door is obtained; S501, wherein the anti-corrosion coating is made of 12 parts of water-based resin, 8 parts of polydimethylsiloxane, 1.5 parts of mica powder, 5 parts of silicone-modified styrene-acrylic emulsion, 2 parts of sodium polyphosphate and wetting dispersant, 8 parts of bactericide, 5 parts of pH adjuster, 6.5 parts of film-forming aid and 4.5 parts of stabilizer; during preparation, the water-based resin and the bactericide are mixed evenly and stirred for 8 minutes, then the dispersant, mica powder and styrene-acrylic emulsion are added and mixed, then the film-forming aid, pH adjuster and stabilizer are added and stirred and dispersed evenly, and finally the aforementioned anti-corrosion coating is obtained.

[0029] Different from the prior art, the anti-corrosion wooden door and the manufacturing method thereof of the present application can make the manufactured wooden door have excellent anti-corrosion, moisture-proof and mildew-proof properties, and is suitable for easily corrosive environments such as seaside villas, bathrooms and basements.

[0030] It should be understood that in the various embodiments of this document, the size of the serial numbers of the above-mentioned processes does not mean the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this document.

[0031] It should also be understood that in the embodiments of this article, the term "and / or" is only a description of the association relationship of the associated objects, indicating that three relationships may exist. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in this article generally indicates that the associated objects before and after are in an "or" relationship.

[0032] Those of ordinary skill in the art will appreciate that the units and algorithm steps of each example described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of the two. In order to clearly illustrate the interchangeability of hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are performed in hardware or software depends on the specific application and design constraints of the technical solution. Professional and technical personnel can use different methods to implement the described functions for each specific application, but such implementation should not be considered to be beyond the scope of this article.

[0033] Those skilled in the art can clearly understand that, for the convenience and brevity of description, the specific working processes of the systems, devices and units described above can refer to the corresponding processes in the aforementioned method embodiments and will not be repeated here.

[0034] In the several embodiments provided herein, it should be understood that the disclosed systems, devices and methods can be implemented in other ways. For example, the device embodiments described above are only schematic, for example, the division of the units is only a logical function division, and there may be other division methods in actual implementation, such as multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. In addition, the mutual coupling or direct coupling or communication connection shown or discussed can be an indirect coupling or communication connection through some interfaces, devices or units, or can be electrical, mechanical or other forms of connection.

[0035] The units described as separate components may or may not be physically separated, and the components shown as units may or may not be physical units, that is, they may be located in one place or distributed on multiple network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the embodiments of this article.

[0036] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. An anti-corrosion wooden door, characterized in that: include: The anti-corrosion layer and the strengthening structure layer are stacked in sequence; the anti-corrosion layer is the outer layer of the anti-corrosion wooden door, the strengthening structure layer is the inner layer of the anti-corrosion wooden door, and the anti-corrosion layer and the strengthening structure layer are combined with each other.

2. The anti-corrosion wooden door according to claim 1, characterized in that: The anti-corrosion layer is made of a composite material of high-density polyethylene and stainless steel fibers; The mass proportion of the high-density polyethylene is 80%-90%; The mass proportion of the stainless steel fiber composite material is 10%-20%.

3. The anti-corrosion wooden door according to claim 1, characterized in that: The reinforcing structure layer comprises: a phenolic resin impregnated paper laminate; the phenolic resin impregnated paper laminate is made of wood fiber, phenolic resin and flame retardant; The mass proportion of the wood fiber is 70%-90%; The mass proportion of the phenolic resin is 8%-25%; The mass proportion of the flame retardant is 2%-5%.

4. The method for manufacturing the anti-corrosion wooden door according to claim 1, characterized in that: The method comprises the following steps: Make anti-corrosion layer and strengthen structural layer; Laminating and assembling the anti-corrosion layer and the strengthening structure layer to obtain a first preliminary door panel; Performing fine anti-corrosion treatment on the first preliminary door panel to obtain a second preliminary door panel; Anti-corrosion paint is applied several times on the surface of the second preliminary door panel and the door frame to obtain a finished anti-corrosion wooden door.

5. The manufacturing method according to claim 4, characterized in that: The method of making the anti-corrosion layer and the strengthening structure layer comprises: The stainless steel fibers are evenly dispersed in the molten HDPE, and a composite material is made through an extrusion molding process to obtain a preliminary anti-corrosion layer.

6. The manufacturing method according to claim 5, characterized in that: The method of making the anti-corrosion layer and the strengthening structure layer further comprises: The surface of the preliminary anti-corrosion layer is coated with a special anti-corrosion coating to obtain the anti-corrosion layer; The special anti-corrosion coating comprises: a composite coating with epoxy resin as base material and anti-corrosion pigment and additives added therein.

7. The manufacturing method according to claim 4, characterized in that: The method of making the anti-corrosion layer and the strengthening structure layer further comprises: After the wood fibers are dried and screened, they are impregnated with phenolic resin and cured under high temperature and high pressure to obtain a laminate with moisture-proof and corrosion-resistant properties, and the laminate is used as the reinforcing structural layer.

8. The manufacturing method according to claim 4, characterized in that: The step of laminating and assembling the anti-corrosion layer and the strengthening structure layer to obtain a first preliminary door panel comprises: Cutting and splicing the strengthening structure layer to obtain a basic door leaf frame; A layer of anti-corrosion glue is evenly coated on the surface of the door leaf basic frame, and then the anti-corrosion layer is attached to the door leaf basic frame, and the anti-corrosion layer and the door leaf basic frame are tightly combined by a hot pressing process to obtain the first preliminary door panel; The anti-corrosion glue includes: polyurethane glue.

9. The manufacturing method according to claim 4, characterized in that: The step of performing a fine anti-corrosion treatment on the first preliminary door panel to obtain a second preliminary door panel comprises: The metal parts to be installed on the first preliminary door panel are all subjected to galvanizing or stainless steel surface treatment; The first preliminary door panel is cut and punched, the galvanized or stainless steel surface-treated metal component to be installed is installed at the installation position, and the surface of the first preliminary door panel is polished to obtain the second preliminary door panel.

10. The manufacturing method according to claim 4, characterized in that: The anti-corrosion coating is made of 12 parts of water-based resin, 8 parts of polydimethylsiloxane, 1.5 parts of mica powder, 5 parts of silicone-modified styrene-acrylic emulsion, 2 parts of sodium polyphosphate and a wetting and dispersing agent, 8 parts of a bactericide, 5 parts of a pH regulator, 6.5 parts of a film-forming aid and 4.5 parts of a stabilizer.

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