Door plate top-loading foaming milling-free process

Abstract

The invention relates to the technical field of door plate manufacturing, in particular to a door plate top-loading foaming milling-free process which comprises the following steps: a) selecting a base material of a door plate main body, b) coating a layer of special adhesive on the surface of the door plate main body, c) adhering a layer of protective film on the surface of the door plate main body, d) preparing a foaming material, e) tearing off the protective film before the foaming material is applied to the door plate main body, and e) sealing the door plate main body. And f) after the foaming material is cured, necessary finishing treatment is carried out on the door plate, and the milling-free process simplifies the production process, shortens the production period and improves the production efficiency. Meanwhile, due to the application modes of spraying, pouring and the like and the use of a foaming pouring mold in the preferable technical scheme, the production speed is further increased, wood chips and noise generated in the traditional milling process threaten the health of workers, and according to the milling-free process, the milling process is reduced, so that the health risk of the workers is reduced, and the working environment is improved.

Description

Technical Field

[0001] The invention relates to the technical field of door panel manufacturing, in particular to a milling-free foaming process for door panels. Background Art

[0002] In the traditional door panel manufacturing process, milling is an indispensable part. However, this process is not only time-consuming and labor-intensive, but also increases production costs and reduces production efficiency. At the same time, the wood chips and noise generated during the milling process pollute the environment and pose a threat to the health of workers. Therefore, finding a door panel manufacturing process that can reduce milling processes, reduce production costs, improve production efficiency, and reduce environmental pollution and health risks to workers has become an urgent problem to be solved in the current door panel manufacturing field.

[0003] In the prior art, door panel manufacturing usually includes multiple steps such as substrate selection, adhesive coating, foaming material application, and finishing. The traditional door panel foaming process usually requires milling of the door panel first to ensure that the surface of the door panel is flat and smooth, which is convenient for the subsequent bonding of the foaming material. Although this process can ensure the surface quality of the door panel, it also brings the following major problems:

[0004] Increased production costs: The milling process requires the use of specialized machinery and tools, which increases the investment and maintenance costs of production equipment. At the same time, the materials and energy consumed in the milling process also increase production costs.

[0005] Extended production cycle: The milling process requires extra time to complete, which not only extends the production cycle but may also affect production efficiency and delivery time.

[0006] Environmental pollution: The large amount of dust and debris generated during the milling process pollutes the environment, and additional environmental protection measures are needed to deal with these wastes.

[0007] Health risks: Dust and debris not only pollute the environment, but can also pose a threat to workers’ health. Long-term exposure to these environments may cause respiratory diseases and other health problems. Summary of the invention

[0008] 1. Technical issues to be solved

[0009] In view of the deficiencies in the prior art, the present invention provides a milling-free process for foaming door panels.

[0010] (II) Technical solution

[0011] To achieve the above object, the present invention provides the following technical solution: A milling-free foaming process for door panels of the present invention comprises the following steps:

[0012] a) Selecting a base material of the door panel body, wherein the base material of the door panel body includes any one of solid wood and artificial board;

[0013] b) coating a layer of special adhesive on the surface of the door panel body, the adhesive is used to bond well with the foaming material used later;

[0014] c) a layer of protective film is pasted on the surface of the door panel body, the protective film is used to protect the adhesive on the surface of the door panel body and facilitate the storage of the door panel body after the adhesive is applied;

[0015] d) Prepare a foaming material, wherein the foaming material includes a polypropylene raw material and a baking soda foaming agent, and the two are uniformly mixed.

[0016] e) before applying the foaming material to the door panel body, the protective film is removed, and the foaming material is applied to the door panel body coated with the adhesive;

[0017] f) After the foaming material solidifies, the door panel body shall be subjected to necessary finishing treatment to ensure the appearance quality and performance of the final product.

[0018] Preferably, the foaming material is applied by spraying or pouring.

[0019] Further preferably, the foam material has a thickness of 10 mm to 30 mm.

[0020] Again preferably, the adhesive is applied by spraying or brushing.

[0021] Preferably, a tear-off edge is provided on the side of the protective film, and a plurality of fold lines are provided on the protective film.

[0022] Further preferably, it includes a foaming casting mold, a casting cavity is provided in the foaming casting mold, a bidirectional screw is rotatably installed at the bottom of the casting cavity, a driving motor is installed on the outer wall of the casting mold, the output end of the driving motor is connected to the bidirectional screw, a clamp is provided on the bidirectional screw, a cylinder is installed on the outer wall of the foaming casting mold, the output end of the cylinder passes through the foaming casting mold and extends into the casting cavity, and a limit plate is installed on the output end of the cylinder.

[0023] Preferably again, a protective film is adhered to the surfaces of the limiting plate and the clamping plate.

[0024] Preferably, the bottom of the limiting plate fits with the bottom of the casting cavity, scale lines are provided on both sides of the casting cavity, and the scale lines are located between the clamping plate and the limiting plate.

[0025] (III) Beneficial effects

[0026] Compared with the prior art, the present invention provides a milling-free foaming process for door panels, which has the following beneficial effects:

[0027] Reduce production costs:

[0028] By reducing the milling process in the traditional process, the material waste and processing time in the production process are directly reduced, thereby effectively reducing the production cost.

[0029] Improved production efficiency:

[0030] The milling-free process simplifies the production process, shortens the production cycle, and improves production efficiency. At the same time, the application methods such as spraying and pouring in the preferred technical solution and the use of foaming casting molds further speed up the production speed.

[0031] Improve product quality:

[0032] The use of special adhesives enhances the bonding force between the foam material and the door panel body, ensuring that the foam material is firmly attached to the door panel, thus improving the stability and durability of the product.

[0033] By precisely controlling the thickness and uniformity of the foaming material and subsequent finishing, the smoothness and appearance quality of the door panel surface are ensured.

[0034] Reduce environmental pollution:

[0035] The milling-free process reduces the generation of wood chips and waste, and reduces environmental pollution. At the same time, the selection of foam materials and the optimization of application methods also reduce the emission of harmful substances.

[0036] Reduces Health Risks:

[0037] The wood chips and noise generated in the traditional milling process pose a threat to workers' health. The milling-free process reduces the health risks of workers and improves the working environment by reducing the milling process.

[0038] Enhanced product performance:

[0039] The uniform expansion of the foam material and the formation of a stable foam layer improve the thermal and sound insulation performance of the door panel. At the same time, by controlling the thickness of the foam material, the performance of the product is further optimized.

[0040] Easy operation and maintenance:

[0041] The protective film design, the use of foam casting molds and the setting of scale lines in the preferred technical solution make the entire process easier to operate and maintain, and improve production efficiency and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1This is a schematic diagram of the door panel structure of the present invention;

[0043] Figure 2 This is a schematic diagram of the structure of the door panel pasted with a protective film according to the present invention;

[0044] Figure 3 This is a schematic diagram of the foaming casting mold structure of the present invention;

[0045] Figure 4 It is a schematic diagram of the process structure of the present invention;

[0046] In the figure: 1. Door panel body; 2. Adhesive; 3. Protective film; 4. Tear-off edge; 5. Fold line; 6. Foam casting mold; 7. Casting cavity; 8. Bidirectional screw rod; 9. Limit plate; 10. Drive motor; 11. Clamp; 12. Cylinder; 13. Scale line. DETAILED DESCRIPTION

[0047] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0048] See also Figure 1-4 The present invention provides a milling-free foaming process for door panels, comprising the following steps:

[0049] a) selecting a base material of the door panel body 1, wherein the base material of the door panel body 1 includes any one of solid wood and artificial board;

[0050] b) coating a layer of special adhesive 2 on the surface of the door panel body 1, wherein the adhesive 2 is used to bond well with the foaming material used later;

[0051] c) A protective film 3 is pasted on the surface of the door panel body 1, wherein the protective film 3 is used to protect the adhesive 2 on the surface of the door panel body 1 and facilitate the storage of the door panel body 1 after the adhesive 2 is applied;

[0052] d) Prepare a foaming material, wherein the foaming material includes a polypropylene raw material and a baking soda foaming agent, and the two are uniformly mixed.

[0053] e) before applying the foaming material to the door panel body 1, the protective film 3 is removed, and the foaming material is applied to the door panel body 1 coated with the adhesive 2;

[0054] f) After the foaming material is cured, the door panel body 1 is subjected to necessary finishing treatment to ensure the appearance quality and performance of the final product.

[0055] The door panel foaming milling-free process aims to reduce production costs and improve production efficiency by reducing the milling process in traditional processes, while reducing environmental pollution and health risks to workers. The specific working principle is as follows:

[0056] Select the base material of the door panel body 1:

[0057] Base material selection: Select an appropriate base material as the door panel body 1, and the base material can be solid wood or artificial board.

[0058] Working principle: The choice of substrate directly affects the strength and stability of the door panel, ensuring that the door panel will not deform during subsequent processing.

[0059] A layer of special adhesive 2 is applied on the surface of the door panel body 1:

[0060] Function of adhesive 2: Adhesive 2 is used to bond well with the foaming material used subsequently, and also has certain weather resistance and corrosion resistance.

[0061] Working principle: By applying adhesive 2, the bonding force between the foaming material and the door panel body 1 is enhanced to ensure that the foaming material is firmly attached to the door panel after curing.

[0062] A protective film 3 is pasted on the surface of the door panel body 1:

[0063] Function of the protective film 3: The protective film 3 is used to protect the adhesive 2 on the surface of the door panel body 1 and facilitate the storage of the door panel body 1 after being coated with the adhesive 2.

[0064] Working principle: The protective film 3 prevents the adhesive 2 from being contaminated or dried out during storage, ensuring the activity of the adhesive 2 when in use.

[0065] Prepare foaming material:

[0066] Composition of foaming material: The foaming material includes polypropylene raw material and baking soda foaming agent, and the two are evenly mixed.

[0067] Working principle: By evenly mixing the polypropylene raw material and the baking soda foaming agent, it is ensured that the foaming material can expand evenly during the application process to form a stable foam layer.

[0068] Remove the protective film 3 before applying the foaming material to the door panel body 1:

[0069] Removing the protective film 3: Before applying the foaming material to the door panel body 1, the protective film 3 is removed to expose the door panel surface coated with the adhesive 2.

[0070] Working principle: After removing the protective film 3, ensure that the foaming material can directly contact and adhere to the adhesive 2 on the surface of the door panel.

[0071] After the foam material solidifies, the door panel needs to be trimmed as necessary:

[0072] Finishing: After the foam material solidifies, the door panel needs to be finished to ensure the appearance quality and performance of the final product.

[0073] Working principle: Through trimming treatment, remove excess foaming materials and burrs to ensure that the surface of the door panel is flat and smooth.

[0074] How the Optimal Technology Solution Works

[0075] Application method of foam material:

[0076] Application method: The foam material is applied by spraying or pouring.

[0077] Working principle: Spraying is suitable for large-area uniform application, while pouring is suitable for local or complex-shaped application. Choosing a suitable application method can improve the coverage uniformity and adhesion of the foaming material.

[0078] Thickness of foam material:

[0079] Thickness range: The thickness of the foam material is 10mm to 30mm.

[0080] Working principle: By controlling the thickness of the foaming material, it is ensured that the foaming layer has good heat insulation and sound insulation properties, while avoiding waste caused by excessive thickness and insufficient performance caused by excessive thinness.

[0081] Adhesive 2 coating method:

[0082] Coating method: The adhesive 2 can be coated by spraying or brushing.

[0083] Working principle: Spraying is suitable for fast and uniform coating, while brushing is suitable for local or fine coating. Choosing a suitable coating method can improve the coverage and uniformity of adhesive 2.

[0084] Design of Protective Film 3:

[0085] Tear-off edge 4 and fold line 5: A tear-off edge 4 is provided on the side of the protective film 3, and a plurality of fold lines 5 are provided on the protective film 3.

[0086] Working principle: The tear-off edge 4 facilitates quick tearing off of the protective film 3, and the fold line 5 facilitates folding and storage, ensuring that the protective film 3 is easy to operate during use.

[0087] Foam casting mold 6:

[0088] Mould structure: including a foaming casting mould 6, a casting cavity 7 is provided in the foaming casting mould 6, a bidirectional screw 8 is rotatably installed at the bottom of the casting cavity 7, a driving motor 10 is installed on the outer wall of the casting mould, the output end of the driving motor 10 is connected to the bidirectional screw 8, a clamping plate 11 is sleeved on the bidirectional screw 8, a cylinder 12 is installed on the outer wall of the foaming casting mould 6, the output end of the cylinder 12 penetrates the foaming casting mould 6 and extends into the casting cavity 7, and a limiting plate 9 is installed on the output end of the cylinder 12.

[0089] Working principle: The driving motor 10 drives the bidirectional screw 8 to rotate, so that the clamping plate 11 moves and fixes the door panel body 1; the cylinder 12 drives the limit plate 9 to move up and down to ensure that the foaming material is evenly distributed during the pouring process and improve the filling effect of the foaming material.

[0090] Protective film of the limiting plate 9 and the clamping plate 11:

[0091] Protective film: A protective film is pasted on the surfaces of the limiting plate 9 and the clamping plate 11.

[0092] Working principle: The protective film prevents the limit plate 9 and the clamping plate 11 from scratching the surface of the door panel during use, thereby ensuring the integrity of the surface of the door panel.

[0093] Fitting of the limiting plate 9 and the casting cavity 7:

[0094] Fitting design: the bottom of the limiting plate 9 fits with the bottom of the casting cavity 7 , scale lines 13 are provided on both sides of the casting cavity 7 , and the scale lines 13 are located between the clamping plate 11 and the limiting plate 9 .

[0095] Working principle: the limit plate 9 fits with the bottom of the casting cavity 7 to ensure that the foaming material is not disturbed by the outside world during the curing process; the scale line 13 is used to accurately control the position of the clamping plate 11 to ensure the stability and uniformity of the door panel body 1 during the casting process.

[0096] Summarize

[0097] The present invention provides a milling-free foaming process for door panels, which reduces the milling process in the traditional process, reduces production costs, improves production efficiency, and reduces environmental pollution and health risks to workers. The preferred technical solution further optimizes each link of the process and ensures the quality and performance of the final product.

[0098] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A milling-free foaming process for door panels, characterized in that: The following steps are involved: a) selecting a base material of the door panel body (1), wherein the base material of the door panel body (1) includes any one of solid wood and artificial board; b) coating a layer of a special adhesive (2) on the surface of the door panel body (1), wherein the adhesive (2) is used to be well bonded with the foaming material used subsequently; c) a layer of protective film (3) is pasted on the surface of the door panel body (1), wherein the protective film (3) is used to protect the adhesive (2) on the surface of the door panel body (1) and facilitate the storage of the door panel body (1) after being coated with the adhesive (2); d) Prepare a foaming material, wherein the foaming material includes a polypropylene raw material and a baking soda foaming agent, and the two are uniformly mixed. e) before applying the foaming material to the door panel body (1), the protective film (3) is removed, and the foaming material is applied to the door panel body (1) coated with the adhesive (2); f) After the foaming material is solidified, the door panel body (1) is subjected to necessary finishing treatment to ensure the appearance quality and performance of the final product.

2. A milling-free foaming process for door panels according to claim 1, characterized in that: The foaming material is applied by spraying or pouring.

3. A milling-free foaming process for door panels according to claim 2, characterized in that: The thickness of the foaming material is 10 mm to 30 mm.

4. A milling-free foaming process for door panels according to claim 3, characterized in that: The adhesive (2) is applied by spraying or brushing.

5. A milling-free foaming process for door panels according to claim 4, characterized in that: The side of the protective film is provided with a tear-off edge (4), and the protective film (3) is provided with a plurality of fold lines (5).

6. A milling-free foaming process for door panels according to claim 5, characterized in that: The invention comprises a foaming casting mold (6), wherein a casting cavity (7) is provided in the foaming casting mold (6), a bidirectional screw (8) is rotatably mounted at the bottom of the casting cavity (7), a driving motor (10) is mounted on the outer wall of the casting mold, the output end of the driving motor (10) is connected to the bidirectional screw (8), a clamping plate (11) is sleeved on the bidirectional screw (8), a cylinder (12) is mounted on the outer wall of the foaming casting mold (6), the output end of the cylinder (12) penetrates the foaming casting mold (6) and extends into the casting cavity (7), and a limit plate (9) is mounted on the output end of the cylinder (12).

7. The milling-free foaming process for door panels according to claim 6 is characterized in that: Protective films are pasted on the surfaces of the limiting plate (9) and the clamping plate (11).

8. The milling-free foaming process for door panels according to claim 7 is characterized in that: The bottom of the limiting plate (9) fits the bottom of the casting cavity (7), scale lines (13) are provided on both sides of the casting cavity (7), and the scale lines (13) are located between the clamping plate (11) and the limiting plate (9).

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