Novel cabinet tabletop manufacturing process and method

Abstract

The invention discloses a novel cabinet table board manufacturing process and method. The process comprises the following steps that 1, a rock plate and a base material are compounded and cured to form a composite board; 2, the composite board is cut, and it is ensured that the section is perpendicular and smooth; step 3, coating PUR glue on the cutting surface of the composite board; the method comprises the steps that firstly, a composite board is manufactured, secondly, the composite board is cut, fourthly, prefabricated edge sealing strips with the thickness ranging from 2.0 mm to 3.0 mm are pressed and attached to the cut face of the composite board, edge sealing of a table top is completed, fifthly, chamfering, edge grinding and offset printing cleaning are conducted on a composite product formed in the fourth step, the seamless edge covering effect is achieved, and one or more of a honeycomb aluminum board, a density fiberboard, a shaving board, a hard wood board and a PVC foaming board is selected as a base material. The invention aims to solve the problems that in the prior art, when the edge of a cabinet is sealed, the thickness of an edge sealing strip is too small, so that the corners of a rock plate cannot be effectively protected, and edge breakage and corner breakage are easily caused by collision of hard objects.

Description

Technical Field

[0001] The present invention relates to the technical field of rock slab countertop processing, and in particular to a novel cabinet countertop manufacturing process and method. Background Art

[0002] As people's demands for greater functionality and aesthetics in their kitchens continue to rise, traditional countertop manufacturing processes are exposing numerous shortcomings. For example, quartz countertop joints easily harbor dirt and grime, marble countertops lack stain and wear resistance, and artificial stone countertops have limited heat resistance. These shortcomings make it difficult to meet modern consumers' demand for high-quality, long-lasting countertops. Furthermore, in the context of promoting green environmental protection, traditional processes such as glue and resin, which cause formaldehyde emissions and environmental pollution, also urgently need to be addressed. Therefore, developing new countertop manufacturing processes and methods that balance functionality, environmental friendliness, and aesthetics has become an inevitable trend for the industry to break through development bottlenecks and meet market demand.

[0003] Due to its excellent physical properties and decorative effects, stone slabs are widely used in cabinets, bathrooms, office countertops and other fields.

[0004] The invention patent with application number: CN202210832994.8 and publication number: CN115157787A (hereinafter referred to as "prior art 1") discloses an integrated rock board furniture board, a preparation method thereof, and an edge sealing adhesive for the furniture board. The integrated rock board furniture board includes a thin rock board surface layer, an adhesive layer, an oriented strand board bottom layer, and a bottom sealing film layer arranged in sequence from top to bottom; wherein, the side of the furniture board is adhered with an edge banding strip by a special edge banding adhesive.

[0005] The specification of prior art 1 discloses an integrated rock slab furniture board, a preparation method thereof, and an edge-sealing adhesive for the furniture board. When used, the composite board is edge-sealed using edge-sealing strips in the prior art. However, in actual applications, the processing of traditional rock slab countertops has the following problems: 1. Edges and corners are easily damaged: The existing PVC edge banding is relatively thin (0.6-1.0mm), which cannot effectively protect the edges and corners of the rock slabs and is prone to edge and corner collapse due to collision with hard objects.

[0006] 2. High processing cost: Traditional processes rely on manual bonding, which is inefficient and produces dust and wastewater. The processing cost is significantly higher than that of materials such as stone and glass.

[0007] 3. Lack of aesthetics: The edge banding does not match the color and texture of the rock slab, affecting the overall decorative effect. Summary of the Invention The present invention provides a new cabinet countertop manufacturing process and method, the purpose of which is to solve the problem in the prior art that the thickness of the edge banding strips when sealing the cabinets is too small, which makes it impossible to effectively protect the edges and corners of the rock slabs, and is prone to edge and corner collapse due to collision with hard objects.

[0008] In order to solve the above technical problems, the technical solution adopted by the present invention is: A novel cabinet countertop manufacturing process includes the following steps: Step 1: Composite the rock plate and the base material to form a composite plate after curing; Step 2: cutting the composite board to ensure that the cut surface is vertical and smooth; Step 3: Apply PUR glue on the cut surface of the composite board; Step 4: Press a 2.0-3.0 mm thick prefabricated edge banding strip onto the cut surface of the composite board to complete the edge banding of the countertop.

[0009] Furthermore, the steps also include: step 5, chamfering, grinding, and cleaning the offset printing of the composite product formed in step 4 to form a seamless edge effect.

[0010] Furthermore, the substrate is selected from one or more of honeycomb aluminum panels, density fiberboards, particleboards, hardwood panels, and PVC foam panels.

[0011] Furthermore, in step 4, the prefabricated edge banding used includes a process as follows: Step 401: Prepare polyvinyl chloride, pigment, calcium powder and additives; Step 402: placing the material in step 401 into a die of an extruder; Step 403: Starting an extruder to extrude the material in step 401 to form the prefabricated edge banding strip.

[0012] Furthermore, in step 401, 80%-90% polyvinyl chloride, 9%-11% calcium powder, 2%-4% pigment, and 1.8%-2.2% additive are prepared according to mass ratio and put into a mold of an extruder.

[0013] Furthermore, in step 1, the curing time between the rock slab and the substrate is 45-51 hours.

[0014] Furthermore, in step 2, the composite material is cut using a diamond saw blade so that the surface roughness after cutting is ≤0.1 mm.

[0015] Furthermore, in step 4, PUR hot melt adhesive is applied to the edge banding machine, and after the edge banding strip is pressed, the edge is chamfered at 45° and polished with 500-700 grit sandpaper.

[0016] Furthermore, in step 4, the width of the edge banding is 30-45 mm.

[0017] The present invention also relates to a novel method for manufacturing a cabinet countertop, the specific steps of which are as follows: Step A: First laminate the rock board onto the PVC foam board and wait for the curing balance; Step B: Use a high-speed saw to cut the rock slab and PVC foam board together according to the required size of the countertop, making the cut surface vertical and smooth; Step C: After the moisture on the incision surface evaporates, clean the dust on the incision surface; Step D: Feed the cut surface of the composite material and the prefabricated edge banding strips into the edge banding machine. The edge banding machine will evenly apply PUR glue on the cut surface of the composite material, while the edge banding strips are pressed onto the cut surface on the extruder. Step E: After chamfering, edge grinding, tracking chamfering and other actions, the ideal edging effect is achieved; Step F: Finally, manually clean the surface offset print and pack it for storage.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] The present invention firstly exposes the PVC side at the edges and corners by thickening the edge banding strips (2.0-3.0mm), effectively resisting collisions with hard objects and reducing the risk of damage to the rock slabs. The edge banding strips of this edging process have a thickness of 2.0-3.0mm. After the edge banding and chamfering, the sides of the 2.0-3.0mm edge banding strips at the four corners and corners of the countertop are exposed. If other hard objects collide with the edges or corners of the countertop, the front and sides of the PVC will contact the hard objects. This effectively protects the rock slab from being damaged by hard objects and causing chipping of corners, edges and surfaces. Compared with ordinary PVC edge banding strips, the thickness is generally 0.6-1.0mm. Such PVC edge banding is difficult to play the role of protecting the edges and corners of the rock slabs; secondly, through the automated process, that is, the automatic edge banding machine, the efficiency is 100 times that of the traditional process, and there is no wastewater or dust pollution; finally, by simplifying the processing steps, labor and material costs are reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0021] Figure 1 It is a structural schematic diagram of the present invention.

[0022] Figure 2 It is a process flow chart of the present invention.

[0023] Figure 3 This is a table showing the impact test data of the substrate in the present invention.

[0024] In the figure, 101 is a rock board, 102 is a base material, and 103 is an edge banding strip. DETAILED DESCRIPTION

[0025] The present invention will be further described below with reference to the embodiments. The embodiments described are only a part of the embodiments of the present invention and are not all embodiments. Based on the embodiments of the present invention, other embodiments obtained by ordinary technicians in this field without making creative work are all within the scope of protection of the present invention.

[0026] See also Figure 1 as well as Figure 2 As shown, this embodiment discloses a novel cabinet countertop manufacturing process, comprising the following steps: Step 1: Composite the rock plate 101 and the base material 102 and solidify them to form a composite plate; Step 2: cutting the composite board to ensure that the cut surface is vertical and smooth; Step 3: Apply PUR glue on the cut surface of the composite board; Step 4: Press a prefabricated edge banding strip 103 with a thickness of 2.0-3.0 mm onto the cut surface of the composite board to complete the edge banding of the countertop.

[0027] The present invention first exposes the PVC side at the corners and external corners by thickening the edge banding 103 (2.0-3.0mm), effectively resisting collisions with hard objects and reducing the risk of damage to the rock board 101. The edge banding 103 of this edge banding process has a thickness of 2.0-3.0mm. After the edge banding and chamfering, the sides of the 2.0-3.0mm edge banding 103 at the four corners and external corners of the countertop are exposed to the outside. If other hard objects collide with the corners or external corners of the countertop, the front and side surfaces of the PVC are in contact with the hard objects. This effectively protects the rock board 101 from being damaged by hard objects and causing corner, edge and surface collapse. Compared with ordinary PVC edge banding 103, its thickness is generally 0.6-1.0mm. Such PVC Edge banding can hardly protect the edges and corners of the rock slabs; secondly, through automated processes, that is, automatic edge banding machines, the efficiency is a hundred times that of traditional processes, and there is no wastewater or dust pollution; finally, by simplifying the processing steps, labor and material costs are reduced.

[0028] In some embodiments, the steps further include: step 5, chamfering, grinding, and cleaning the offset printing of the composite product formed in step 4 to form a seamless edging effect.

[0029] In actual use, this edge-sealing process has high production efficiency, hundreds of times more efficient than traditional rock slab 101 processing and bonding processes. Furthermore, it produces no wastewater or dust during the production process, and the finished edge-sealing effect is even more beautiful than traditional jointing processes, making it highly worthy of promotion and application.

[0030] In some embodiments, the substrate 102 is selected from one or more of a honeycomb aluminum board, a density fiberboard, a particleboard, a hardwood board, and a PVC foam board.

[0031] See also Figure 1-Figure 3 As shown, as an optional implementation, in this embodiment, honeycomb aluminum panels, density fiberboards, particleboards, hardwood boards, PVC foam boards and rock panels 101 are respectively used for curing and compounding, and collision tests are performed on each material respectively; The experimental process is as follows: Step a: First, select the honeycomb aluminum plate as the test object, and the specification of the rock plate 101 is uniformly selected as 6mm thick matte surface rock plate 101; Step b: Use a 500g standard steel ball to impact the honeycomb aluminum plate laid on a flat surface, with the impact height increasing from 50cm to 120cm until the honeycomb aluminum plate breaks; Step c: Select the impact point, which is the edge of the joint between the edge banding strip 103 and the rock slab 101; Step d: Conduct a steel ball drop test and record the experimental data; Step e: replacing the test objects in step a with density fiberboard, particleboard, hardwood board, and PVC foam board, and repeating step be; The experimental data table is as follows:

[0032] Based on the above experimental data, it is concluded that the impact resistance of the honeycomb aluminum plate is the best. Therefore, the base material 102 in step 1 is a honeycomb aluminum plate.

[0033] In some embodiments, in step 4, the prefabricated edge banding 103 is made using the following process: Step 401: Prepare polyvinyl chloride, pigment, calcium powder and additives; Step 402: placing the material in step 401 into a die of an extruder; Step 403: The prefabricated edge banding strip 103 is formed by starting an extruder to extrude the material in step 401 .

[0034] In some embodiments, in step 401, 80%-90% polyvinyl chloride, 9%-11% calcium powder, 2%-4% pigment, and 1.8%-2.2% additive are prepared according to mass ratio and placed into a mold of an extruder.

[0035] As an optional implementation, in this embodiment, 85% polyvinyl chloride, 10% calcium powder, 3% pigment, and 2% additive are prepared according to the mass ratio, placed in the mold of the extruder, and extruded at 180°C and 15MPa to form a composite board. Compared with using glue for bonding, the extrusion molding is obviously more stable.

[0036] In some embodiments, in step 1, the curing time between the rock plate 101 and the substrate 102 is 45-51 hours.

[0037] As an optional implementation, in this embodiment, the curing time between the rock plate 101 and the substrate 102 is 48 hours.

[0038] In some embodiments, in step 2, the composite material is cut using a diamond saw blade so that the surface roughness after cutting is ≤0.1 mm.

[0039] In actual use, the surface roughness after cutting is ≤0.1mm, which can make the cut surface of the composite material smoother and facilitate subsequent use.

[0040] In some embodiments, in step 4, PUR hot melt adhesive is applied to the edge banding machine, and after the edge banding strip 103 is pressed, the edge is chamfered at 45° and sanded with 500-700 grit sandpaper.

[0041] In actual use, PUR hot melt adhesive is applied to the edge banding machine and the edge banding strip 103 is pressed onto the end of the composite material to complete the edge banding of the composite material. After that, the edge is chamfered at 45° and then ground with 600-grit sandpaper to complete the installation of the edge banding strip 103.

[0042] In some embodiments, in step 4, the width of the edge banding 103 is 30-45 mm.

[0043] As an optional implementation, in this embodiment, the width of the edge banding strip 103 is 30 mm, 35 mm, 40 mm, or 45 mm.

[0044] In some different embodiments, the present invention also relates to a novel method for manufacturing a cabinet countertop, the specific steps of which are as follows: Step A: First, laminate the rock board 101 onto the PVC foam board and wait for the solidification balance; Step B: Use a high-speed saw blade to cut the rock slab 101 and the PVC foam board together according to the required size of the countertop, so that the cut surface is vertical and smooth; Step C: After the moisture on the incision surface evaporates, clean the dust on the incision surface; Step D: The cut surface of the composite material and the prefabricated edge banding strip 103 are fed into the edge banding machine. The edge banding machine evenly applies PUR glue on the cut surface of the composite material. At the same time, the edge banding strip 103 is pressed onto the cut surface on the extruder. Step E: After chamfering, edge grinding, tracking chamfering and other actions, the ideal edging effect is achieved; Step F: Finally, manually clean the surface offset print and pack it for storage.

[0045] In some different embodiments, the present invention also relates to an adhesive for replacing PUR glue. The components of the adhesive include, by mass, 25 parts of polyether sulfonate water-based polyurethane dispersion, 15 parts of modified phosphate aluminum adhesive, 25 parts of acrylic emulsion, 4 parts of filler (light calcium carbonate), 2.5 parts of thickener, 1 part of defoamer, 3 parts of epoxy polyurethane crosslinker, and 2 parts of nanocellulose (CNF); Compared with the adhesive in prior art 1, the amount of polyether sulfonate aqueous polyurethane dispersion is increased from 22 parts to 25 parts, a 5% increase in dosage, which improves film-forming properties and toughness. In terms of process, the acetone dissolution step is eliminated and replaced with direct high-pressure homogenization dispersion, thereby effectively avoiding solvent residues that may cause a weak interface layer. The original modified aluminum phosphate adhesive was increased from 12 parts to 15 parts. Increasing the component opening can increase the crosslinking density (the amount of boric acid added was increased to 7g / 100ml), and adding 1% silane coupling agent (KH-550) to enhance the bonding with the inorganic filler. The acrylic emulsion content was reduced from 28 to 25 parts, and a core-shell acrylic emulsion was used instead, which can better balance initial adhesion and heat resistance. Reducing the filler (light calcium carbonate) from 6 parts to 4 parts can reduce the amount of filler used and avoid stress concentration. In addition, 4 parts of light calcium carbonate can be replaced with nano-silica (2 parts) + calcium carbonate (2 parts) to improve thixotropy and rigidity. The thickener was changed to an associative polyurethane thickener, and the proportion was reduced from 3 to 2.5. This setting reduces the viscosity under high shear, which is conducive to coating; it recovers quickly after standing and prevents sagging; Three parts of epoxy polyurethane crosslinker and two parts of nanocellulose are added; when used, the epoxy polyurethane crosslinker can react with Al-OH in phosphate aluminum gel and -NCO in polyurethane to form an interpenetrating network; nanocellulose can enhance the anchoring effect on PCV foam board.

[0046] In the description of the present invention, it should be understood that the terms "coaxial", "bottom", "one end", "top", "middle", "the other end", "upper", "one side", "top", "inside", "front", "center", "two ends", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0047] In some different embodiments, during the extrusion molding process of the composite board, a steel film embossing process is used. During the extrusion molding process, a surface texture with the same texture as the rock slab 101 is left on the surface of the edge banding strip 103. The color of each edge banding strip 103 also needs to be formulated into a similar pattern color according to the color of the rock slab 101. In this way, the edge banding strip 103 is very close to the surface effect of the rock slab 101 in terms of color, pattern and texture.

[0048] In addition, the terms "first", "second", "third" and "fourth" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first", "second", "third" and "fourth" may explicitly or implicitly include at least one such feature.

[0049] In the present invention, unless otherwise clearly stipulated and limited, the terms such as "installation", "setting", "connection", "fixation" and "screw-on" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integrated connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. Unless otherwise clearly defined, ordinary technicians in this field can understand the specific meanings of the above terms in the present invention according to the specific circumstances.

[0050] While 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 these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A new cabinet countertop manufacturing process, characterized in that: The steps include: Step 1: Composite the rock plate and the base material to form a composite plate after curing; Step 2: cutting the composite board to ensure that the cut surface is vertical and smooth; Step 3: Apply PUR glue on the cut surface of the composite board; Step 4: Press a 2.0-3.0 mm thick prefabricated edge banding strip onto the cut surface of the composite board to complete the edge banding of the countertop.

2. A novel cabinet countertop manufacturing process according to claim 1, characterized in that: The steps also include: step 5, chamfering, edge grinding, and cleaning offset printing on the composite product formed in step 4 to form a seamless edge effect.

3. The novel cabinet countertop manufacturing process according to claim 1, characterized in that: The substrate is selected from one or more of a medium honeycomb aluminum board, a density fiberboard, a particleboard, a hardwood board, and a PVC foam board.

4. The novel cabinet countertop manufacturing process according to claim 1 is characterized in that: In step 4, the prefabricated edge banding used includes the following process: Step 401: Prepare polyvinyl chloride, pigment, calcium powder and additives; Step 402: placing the material in step 401 into a die of an extruder; Step 403: Starting an extruder to extrude the material in step 401 to form the prefabricated edge banding strip.

5. The novel cabinet countertop manufacturing process according to claim 4 is characterized in that: In step 401, 80%-90% polyvinyl chloride, 9%-11% calcium powder, 2%-4% pigment, and 1.8%-2.2% additive are prepared according to mass ratio and placed into a mold of an extruder.

6. The novel cabinet countertop manufacturing process according to claim 1 is characterized in that: In step 1, the curing time between the rock slab and the substrate is 45-51h.

7. The novel cabinet countertop manufacturing process according to claim 1 is characterized in that: In step 2, the composite material is cut using a diamond saw blade so that the surface roughness after cutting is ≤0.1 mm.

8. The novel cabinet countertop manufacturing process according to claim 1 is characterized in that: In step 4, apply PUR hot melt adhesive on the edge banding machine, press the edge banding strip, and then perform 45° chamfering and 500-700 grit sandpaper to grind the edges.

9. The novel cabinet countertop manufacturing process according to claim 1, characterized in that: In step 4, the width of the edge banding is 30-45 mm.

10. A novel method for manufacturing a cabinet countertop, comprising using a novel method for manufacturing a cabinet countertop according to any one or more of claims 1 to 9, characterized in that: The specific steps are as follows: Step A: First laminate the rock board onto the PVC foam board and wait for the curing balance; Step B: Use a high-speed saw to cut the rock slab and PVC foam board together according to the required size of the countertop, making the cut surface vertical and smooth; Step C: After the moisture on the incision surface evaporates, clean the dust on the incision surface; Step D: Feed the cut surface of the composite material and the prefabricated edge banding strips into the edge banding machine. The edge banding machine will evenly apply PUR glue on the cut surface of the composite material, while the edge banding strips are pressed onto the cut surface on the extruder. Step E: After chamfering, edge grinding, tracking chamfering and other actions, the ideal edging effect is achieved; Step F: Finally, manually clean the surface offset print and pack it for storage.

Images