Method for manufacturing pet appliance from thermosetting material

Abstract

The invention relates to the technical field of thermosetting materials, in particular to a method for manufacturing a pet appliance from a thermosetting material, which comprises the steps of thermosetting base material selection, mold pretreatment, forming process, demolding treatment and shrinkage rate accounting. Performance is optimized through a biomass composite base material and a nanometer enhancement technology, durability is improved through mold surface modification, texture and smoothness are ensured through step-by-step warm-pressing coupling forming, the VOC content is reduced through microwave vulcanization, and size precision is optimized through finite element simulation. According to the invention, the mechanical strength, the environmental protection performance and the production efficiency of the pet appliance can be remarkably improved, meanwhile, the use requirements in a complex environment are met, and a new direction is provided for application of thermosetting materials.

Description

Technical Field

[0001] The present invention belongs to the technical field of pet product manufacturing and thermosetting material application, and in particular relates to a method for manufacturing pet products made of thermosetting materials. Background Art

[0002] The use of thermoset materials in pet product manufacturing has become a significant development trend. These materials, with their excellent mechanical properties and environmental friendliness, are gradually expanding into various segments of pet product production. However, traditional thermoset products still face numerous technical bottlenecks in practical application: insufficient uniformity in the material's internal microporous structure, complex and cumbersome surface treatment processes, and a lack of dimensional control precision during the molding process. These deficiencies directly lead to poor product performance stability, especially in complex operating environments. Their durability and safety performance cannot meet the quality requirements of high-end pet products.

[0003] From a manufacturing perspective, existing pet product production requires optimization in mold processing, molding methods, and demolding techniques. Specifically, traditional mold surface treatment relies excessively on mechanical polishing or simple sandblasting, making it difficult to achieve precise manufacturing requirements when processing high-finish surfaces or molding complex textures. The single-minded control of temperature and pressure during the molding process results in uneven density distribution within the material, severely impacting the product's mechanical properties and user experience. Furthermore, existing mold release agents are inadequate in improving the adhesion of subsequent coatings, limiting the effectiveness of functionalized surface treatments.

[0004] In view of this, the present invention is proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide a method for making pet supplies from thermosetting materials. By optimizing substrate selection, mold processing technology, molding method, and demolding and shrinkage calculation technical means, the method solves the shortcomings of traditional thermosetting material products in terms of microporous structure uniformity, surface treatment accuracy, molding size control, and environmental performance. The combination of a composite substrate mainly composed of biomass components and nano-enhancement technology significantly improves the mechanical strength and functionality of the product. Through mold surface modification and step-by-step temperature and pressure coupling molding process, the manufacturing requirements of complex textures and high-finish surfaces are met. At the same time, finite element simulation is introduced to optimize dimensional prediction, so that the durability and safety of the product in complex environments are further improved.

[0006] To achieve the above object, the present invention provides a method for making pet supplies from thermosetting materials, comprising the following steps:

[0007] Step S1, selecting a thermosetting substrate: selecting a natural biomass thermosetting material containing more than 70% biomass components and an inorganic composite substrate, or a popcorn-type foaming material, and modifying the material to optimize its performance;

[0008] Step S2, mold pretreatment: polish the mold surface to a finish of Class B or above according to the surface characteristics requirements of the desired product, or use 80-mesh silica gel black silicon carbide sandblasting to generate a diamond-like carbon film coating, thereby improving the mold surface hardness and service life;

[0009] Step S3, molding process: The product is manufactured by adopting a step-by-step molding process or an integrated molding process. Step-by-step molding is achieved by forming independent parts and then hot-pressing them together. Integrated molding is achieved by using a flat-plate hydraulic press to foam the single component.

[0010] Step S4, demoulding treatment: using a self-developed polymer transparent release agent to adjust the demoulding parameters, and combining a microwave secondary vulcanization process to reduce the residual volatile organic compound (VOC) content;

[0011] Step S5, shrinkage calculation: Combine finite element simulation with a real-time feedback module of material rheological parameters to optimize component size design and reduce final product size error.

[0012] Preferably, the step S1 specifically includes:

[0013] Natural biomass thermosetting material is selected as the main base material, and 5-15wt% phosphoric acid is added to activate modified diatomaceous earth, forming directional microporous air-conducting channels inside the material through chemical reactions. This microporous structure not only improves the air permeability of the material, but also enhances its mechanical stability. In addition, for popcorn-like foaming materials, they are impregnated in a nanocellulose fiber suspension before foaming, and the fiber length is controlled in the range of 50-200μm. After infrared drying, the tear strength is increased by 40%, and the open porosity exceeds 85%. This modification process enables the material to have excellent impact resistance while maintaining its lightweight.

[0014] Preferably, the step S2 specifically includes:

[0015] When producing products with a high finish, the mold surface is polished to a finish of Class B or higher. For products with complex textures, 80-mesh silica black silicon carbide sandblasting is used, followed by a vapor deposition process that deposits a 200-500nm thick diamond-like carbon film on the mold surface. This film extends the mold life to over 5,000 cycles, while maintaining a surface roughness Ra fluctuation of less than ±0.2μm, meeting the requirements of long-term, stable production.

[0016] Preferably, the step S3 specifically includes:

[0017] In the step-by-step molding process, the accessories are first formed independently, and then assembled through hot pressing coupling. The hot pressing process is divided into three stages of temperature and pressure control: the temperature of the first stage is set to 130-140°C and the pressure is 8-10MPa; the second stage drops sharply to 70-90°C and the pressure increases to 12-15MPa; the third stage is heated to 110-120°C and the pressure drops to 5-7MPa. The duration ratio of each stage is 3:1:2 to ensure uniform density distribution inside the material. In the one-piece molding process, the flat-plate hydraulic press mold is equipped with a zoned temperature control system. The temperature of the center zone is 15-20°C higher than that of the edge zone, so that the core density of the product is 0.25-0.35g / cm 3 , surface density is 0.45-0.55g / cm 3 The gradient structure takes into account both lightweight and surface strength.

[0018] Preferably, the step S4 specifically includes:

[0019] During the demolding process, a composite emulsion of perfluoropolyether and silicone-modified epoxy resin is used as a release agent. This release agent forms a microporous layer with a thickness of 10-50nm on the product surface, ensuring that the subsequent UV coating has adhesion level 5B (ASTM D3359). After demolding, the product undergoes a secondary vulcanization at 2.45GHz microwaves at 80-90°C, with a power density controlled within the range of 0.5-1W / g. This process shortens the vulcanization time to one-fifth of that of traditional processes while reducing the residual VOC content to below 50ppm, significantly improving the product's environmental performance.

[0020] Preferably, the step S5 specifically includes:

[0021] By embedding a real-time feedback module for material rheological parameters in finite element simulation, key parameters in shrinkage calculations are dynamically adjusted. Specifically, simulation input data is updated in real time based on changes in the vulcanizer torque, keeping the error in final product dimensional prediction within 0.15%. This approach effectively addresses the dimensional deviation issues caused by material shrinkage fluctuations in traditional processes, ensuring that products meet design requirements.

[0022] Preferably, in step S1, a tea polyphenol-rosmarinic acid eutectic antimicrobial compound is added to the natural biomass thermosetting material. This antimicrobial compound interacts with the lignin in the material through a π-π stacking interaction to form a pH-responsive sustained-release system. When the ambient pH is greater than 8, the sustained-release rate increases by three times, thereby imparting long-lasting antimicrobial properties to the product, making it suitable for the hygienic needs of pet supplies.

[0023] The present invention utilizes the aforementioned thermosetting materials to create pet supplies. By comprehensively optimizing substrate modification, mold preparation, molding processes, and subsequent processing techniques, the method significantly improves the product's mechanical properties, environmental performance, and production efficiency, while also reducing manufacturing costs. This method not only meets the requirements for pet supplies used in complex environments but also provides new insights for the application of thermosetting materials in other fields.

[0024] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The drawings described below are only some embodiments. A person skilled in the art can derive other drawings based on these drawings without inventive effort. In the drawings:

[0026] Figure 1 Flow chart of a method for manufacturing pet supplies made of thermosetting materials.

[0027] It should be noted that these drawings and textual descriptions are not intended to limit the conceptual scope of the present invention in any way, but rather to illustrate the concept of the present invention for those skilled in the art by referring to specific embodiments. DETAILED DESCRIPTION

[0028] The present invention will now be described in further detail with reference to the accompanying drawings.

[0029] See also Figure 1 As shown, in this embodiment, a method for making pet supplies made of thermosetting materials is provided, comprising the following steps:

[0030] First, in the process of selecting a thermosetting substrate, a natural biomass thermosetting material containing more than 70% biomass components is selected as the main substrate, and 5-15wt% phosphoric acid-activated modified diatomaceous earth is added to optimize performance; the diatomaceous earth forms directional microporous air-conducting channels inside the material through chemical reactions, giving the material good air permeability and mechanical stability; in addition, if a popcorn-type foaming material is used, it needs to be impregnated in a nanocellulose fiber suspension before foaming, and the fiber length is controlled within the range of 50-200μm; after infrared drying, the material's tear strength is increased by 40%, and the open porosity exceeds 85%; after the above-mentioned substrate is prepared, it needs to be mixed with a tea polyphenol-rosmarinic acid eutectic composite antibacterial agent, which combines with lignin through π-π stacking to form a pH-responsive sustained-release system; this process ensures that the mechanical properties and functionality of the substrate meet the requirements in the subsequent molding process;

[0031] Next comes the mold pretreatment step. Depending on the surface characteristics of the desired product, the mold surface undergoes different treatments. For high-finish products, the mold surface is polished to a finish of Class B or higher. For products with complex textures, 80-mesh silica gel black silicon carbide sandblasting is used, followed by a vapor deposition method that deposits a 200-500nm thick diamond-like carbon film coating. This coating significantly increases the mold surface hardness, extending its service life to over 5,000 cycles, with a surface roughness Ra fluctuation of less than ±0.2μm. After the mold surface treatment is completed, it is cleaned and coated with a non-stick coating to ensure smooth separation between the material and the mold during subsequent molding.

[0032] Then comes the step-by-step molding process, which is divided into two parts: independent component molding and hot-press coupling. When molding independent components, the thermosetting substrate is placed in the mold and the molding is completed through three-stage temperature and pressure control. The temperature is set at 130-140°C and the pressure is 8-10MPa in the first stage. The temperature drops sharply to 70-90°C in the second stage, and the pressure increases to 12-15MPa. The temperature is raised to 110-120°C and the pressure decreases to 5-7MPa in the third stage. The duration ratio of each stage is 3:1:2 to ensure uniform density distribution inside the material. The one-piece molding process uses a flat-plate hydraulic press to complete the manufacturing of the single body. The flat-plate hydraulic press mold is equipped with a zoned temperature control system. The temperature of the center zone is 15-20°C higher than that of the edge zone, so that the core density of the product is 0.25-0.35g / cm 3 , surface density is 0.45-0.55g / cm 3 Gradient structure; this gradient structure takes into account both lightweight and surface strength to meet the use requirements of pet supplies;

[0033] After molding is complete, the release agent is applied. During the demolding process, a composite emulsion of perfluoropolyether and silicone-modified epoxy resin is used as the release agent. This release agent forms a microporous layer with a thickness of 10-50nm on the product surface, enhancing the UV coating adhesion to 5B level. After demolding, the product undergoes secondary vulcanization in a microwave vulcanizer 5 at 80-90°C, with a power density controlled within the range of 0.5-1W / g. The microwave vulcanization process not only shortens the vulcanization time to one-fifth of the traditional process, but also reduces the residual VOC content to below 50ppm, significantly improving the product's environmental performance. The synergistic effect of the release agent and the microwave vulcanizer ensures the product's surface quality and environmental friendliness.

[0034] Finally, the finite element simulation module performs shrinkage calculations. By embedding a real-time feedback module for material rheological parameters, key parameters in shrinkage calculations are dynamically adjusted. Specifically, simulation input data is updated in real time based on changes in the vulcanizer torque, keeping the error in final product dimensional prediction within 0.15%. This approach effectively addresses the dimensional deviation issues caused by material shrinkage fluctuations in traditional processes, ensuring that products meet design requirements. The finite element simulation module is closely integrated with the preceding steps, achieving high-precision predictions of product dimensions through precise control of material properties and process parameters.

[0035] In practical applications, these steps are linked sequentially to ensure the efficiency and reliability of the entire manufacturing process. For example, when producing a pet food bowl with complex textures and a high finish, a modified natural biomass thermoset material is first selected as the base material. The mold is then sandblasted and coated with a diamond-like carbon film. The product is then manufactured through a step-by-step molding process. A release agent is then used to separate the material from the mold. A microwave vulcanization device is then used to reduce VOC content. Finally, a finite element simulation module is used to optimize the dimensional design. Each step is closely linked to form a complete manufacturing system.

[0036] It can be seen from the above specific embodiments that the present invention significantly improves the mechanical properties, environmental characteristics and production efficiency of pet supplies through the comprehensive improvement of the modification treatment of the thermosetting substrate, mold surface treatment technology, molding process optimization and subsequent processing technology; at the same time, the connection relationship, position relationship and mutual coordination relationship between the various components are fully described to ensure that technical personnel in this field can smoothly implement the technical solution according to the contents of the specification.

[0037] The present invention is not limited to the above-described embodiments. Any structural changes made under the guidance of the present invention, which have the same or similar technical solutions as the present invention, should be understood to fall within the scope of protection of the present invention. The technologies, shapes, and structural parts not described in detail in the present invention are all well-known technologies.

Claims

1. A method for making pet supplies made of thermosetting materials, characterized in that: The following steps are involved: Step S1: selecting a natural biomass thermosetting material and an inorganic composite substrate or a popcorn-type foaming material, and modifying the material; Step S2: polishing or coating the mold surface with a diamond-like carbon film according to the surface characteristics of the product; Step S3: Complete product manufacturing by adopting step-by-step molding or integrated molding process. Step-by-step molding is achieved by forming independent parts and then hot-pressing them together. Integrated molding is achieved by foaming with a flat-plate hydraulic press to complete the single-unit manufacturing. Step S4: using a self-developed polymer transparent release agent to adjust the demoulding parameters, and combining a microwave secondary vulcanization process to reduce the residual volatile organic compound content; Step S5: Combine finite element simulation with a real-time feedback module for material rheological parameters to optimize component size design and reduce final product size error.

2. The method for manufacturing pet supplies made of thermosetting materials according to claim 1, characterized in that: The step S1 specifically includes: Natural biomass thermosetting material is selected as the main base material, and 5-15wt% phosphoric acid is added to activate modified diatomaceous earth. Directed microporous air-conducting channels are formed inside the material through chemical reactions. For popcorn-like foaming materials, they are immersed in a nanocellulose fiber suspension before foaming. The fiber length is controlled in the range of 50-200μm. After infrared drying, the tear strength is increased by 40%, and the open porosity exceeds 85%.

3. The method for manufacturing pet supplies made of thermosetting materials according to claim 1, characterized in that: The step S2 specifically includes: When it is necessary to produce products with high finish, the mold surface is polished to achieve a finish standard of Class B or above; if it is necessary to produce products with complex textures, 80-mesh silica gel black silicon carbide sandblasting is used, and then a diamond-like carbon film with a thickness of 200-500nm is generated on the mold surface by vapor deposition.

4. The method for manufacturing pet supplies made of thermosetting materials according to claim 1, characterized in that: The step S3 specifically includes: In the step-by-step molding process, the components are first formed independently, and then assembled through hot pressing coupling. The hot pressing process is divided into three stages of temperature and pressure control. In the first stage, the temperature is set at 130-140°C and the pressure is 8-10MPa. In the second stage, the temperature drops sharply to 70-90°C and the pressure increases to 12-15MPa. In the third stage, the temperature is raised to 110-120°C and the pressure is reduced to 5-7MPa. The duration ratio of each stage is 3:1:

2. In the one-piece molding process, the flat hydraulic press mold is equipped with a zoned temperature control system. The temperature in the center zone is 15-20°C higher than that in the edge zone, so that the core density of the product is 0.25-0.35g / cm 3 , surface density is 0.45-0.55g / cm 3 gradient structure.

5. The method for manufacturing pet supplies made of thermosetting materials according to claim 1, characterized in that: The step S4 specifically includes: During the demolding process, a composite emulsion of perfluoropolyether and silicone-modified epoxy resin is used as a demolding agent, which forms a microporous layer with a thickness of 10-50nm on the surface of the product; after demolding, the product is subjected to 2.45GHz microwave secondary vulcanization at 80-90℃, and the power density is controlled in the range of 0.5-1W / g.

6. The method for manufacturing pet supplies made of thermosetting materials according to claim 1, characterized in that: The step S5 specifically includes: By embedding a real-time feedback module for material rheological parameters in finite element simulation, key parameters in shrinkage calculation are dynamically adjusted, and simulation input data is updated in real time according to changes in the vulcanizer torque, so that the final product size prediction error is controlled within 0.15%.

7. The method for manufacturing pet supplies made of thermosetting materials according to claim 2, characterized in that: A tea polyphenol-rosmarinic acid eutectic composite antibacterial agent is added to the natural biomass thermosetting material. The antibacterial agent and the lignin in the material form a pH-responsive sustained-release system through π-π stacking. When the environmental pH value is greater than 8, the sustained-release rate is increased by 3 times.

8. The method for manufacturing pet supplies made of thermosetting materials according to claim 3, characterized in that: The diamond-like carbon film extends the mold life to more than 5,000 times, and the surface roughness Ra value fluctuation is less than ±0.2μm.

9. The method for manufacturing pet supplies made of thermosetting materials according to claim 4, characterized in that: In the step-by-step molding process, independent parts are molded and then assembled through hot pressing coupling to ensure uniform density distribution inside the material.

10. The method for manufacturing pet supplies made of thermosetting materials according to claim 5, characterized in that: The microwave secondary vulcanization process reduces the residual volatile organic compound content to below 50 ppm.

Images