Door plate structure, electric appliance and foaming and pouring method

Abstract

The invention provides a door plate structure, an electric appliance and a foaming and pouring method. The door plate structure comprises an inner panel and an outer panel. The inner panel is mounted on the outer panel, a foaming material is filled between the inner panel and the outer panel, a flow guide channel is formed between the edge of the inner panel and the edge of the outer panel, and a foaming cavity is formed in the main body part of the inner panel and the main body part of the outer panel; the thickness of the flow guide channel is larger than that of the foaming cavity so that foaming materials can flow from the edge of the panel to the center area in the foaming process. The thickness of the flow guide channel is larger than that of the foaming cavity, a wider flowing path is provided for foaming materials, the foaming materials can smoothly flow to the center area from the edge, and therefore foaming blind areas are prevented from being formed.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of electrical appliances, and particularly relates to a door plate structure, an electrical appliance and a foaming pouring method. BACKGROUND

[0002] The traditional process of the door plate component is that the sponge is pasted on the door plate metal sheet, the door plate inner plate is fixed on the door plate metal sheet by rivets, the door seal is pastively fixed on the door plate inner plate by double-sided adhesive, and finally the sealing is realized by the door seal and the magnetic attraction assembly. The traditional door plate manufacturing process is complex, has many operation steps, consumes long time, and has high labor intensity, which seriously affects the production efficiency. If the door plate adopts the foaming process, the door plate becomes a solid structure, and a metal sheet-foaming layer-metal sheet composite structure is formed. The strength of the door plate is enhanced, but since the foaming material is a fluid with certain viscosity, when the foaming material is poured by the high-pressure foaming machine, the thickness between the inner and outer metal sheets of the door plate is limited, and the flow filling of the foaming material is blocked, and the foaming blind area is easily formed at the edges. SUMMARY

[0003] The present application provides a door plate structure, an electrical appliance and a foaming pouring method, which can solve the technical problem that the foaming material is filled between the inner and outer metal sheets of the panel, the thickness between the panels is limited, and the foaming blind area is easily formed at the edges.

[0004] The present application provides a door plate structure comprising an inner panel and an outer panel.

[0005] The inner panel is mounted on the outer panel, the inner panel and the outer panel are filled with foaming material, a flow guide channel is formed between the edge of the inner panel and the edge of the outer panel, and a foaming cavity is formed in the main body part of the inner panel and the outer panel.

[0006] The thickness of the flow guide channel is greater than the thickness of the foaming cavity, so that the foaming material flows from the edge of the panel to the central area during the foaming process.

[0007] In some embodiments, the outer periphery of the inner panel is connected to the outer panel, the outer periphery of the inner panel is inwardly bent to form an inner step on the outer panel, and the flow guide channel is formed between the inner step, the inner panel and the outer panel.

[0008] In some embodiments, the outer panel is provided with a flange in a direction towards the center of the foaming cavity, the outer periphery of the inner panel is connected to the outer periphery of the flange, the outer periphery of the flange is outwardly bent to form an outer step away from the outer panel, and the flow guide channel is formed between the inner step, the outer step, the inner panel and the outer panel.

[0009] In some embodiments, a gap is provided between the outer periphery of the inner panel and the outer periphery of the flange, and a first seal is arranged in the gap to prevent overflow between the inner panel and the outer panel.

[0010] In some embodiments, a second seal is arranged at the corner of the flow guide channel in the inner wall corner region of the outer panel, and the second seal is used to prevent leakage of the foaming material.

[0011] In some embodiments, the microstructure of the second seal has interconnected pores to allow the second seal to pass and discharge the gas generated during the foaming process.

[0012] In some embodiments, a mounting through hole is provided on the outer panel for mounting a display panel, and a spacer is arranged on the outer panel around the mounting through hole, and the spacer is used to block the flow of the foaming material to the mounting through hole.

[0013] In some embodiments, the mounting through hole is arranged adjacent to the periphery of the outer panel, the spacer includes a U-shaped sponge and a long strip sponge, the long strip sponge has an outer long side abutting the inner side wall of the edge of the outer panel, and the two open ends of the U-shaped sponge are respectively connected to the two ends of the long strip sponge.

[0014] In some embodiments, a sealing elastic member is arranged on the side edge of the inner panel away from the flow guide channel, and the sealing elastic member seals the inner panel and the side panel by elastic deformation.

[0015] In some embodiments, a locking member is arranged on the side of the inner panel away from the foaming cavity, and the locking member releasably connects the door panel structure and the side panel.

[0016] An electric appliance includes a cabinet and a door panel structure, the door panel structure is openably and closably mounted on the cabinet, and the door panel structure is the electric appliance described above.

[0017] A foaming pouring method is used to pour foaming material into a door panel structure, the door panel structure is the door panel structure described above, and the foaming method includes:

[0018] Placing the door panel structure in a limiting tool;

[0019] A mounting through hole is provided on the outer panel, a glue pouring hole is provided on the inner panel or the outer panel, the foaming material is injected from the glue pouring hole, the foaming material flows into the flow guide channel, the foaming reaction and the gelation reaction continue during the flow of the foaming material, and the foaming material completes the mixed opalescent stage in the flow guide channel.

[0020] The foaming material flows from the four sides to the foaming cavity, a parabolic exhaust channel is formed between the flow guide channel, the foaming cavity and the mounting through hole, the gas in the foaming material flows out from the mounting through hole, and the foaming material completes the opalescent expansion stage in the process of flowing in the exhaust channel.

[0021] In some embodiments, the raw material of the foaming material is isocyanate and combined polyether, wherein the mass of the isocyanate is M1, the mass of the combined polyether is M2, and M1:M2=(1.05-1.3):1;

[0022] The mixing time of the isocyanate and the combined polyether in the foaming machine is t1, the mixing time t1≤4s, and the foaming material is injected into the door panel structure through a spray gun;

[0023] The opalescent time of the foaming material is t2, the opalescent time t2 ranges from 6s to 8s, the injection speed ranges from 200g / s to 1000g / s, and the foaming material is injected into the flow guide channel within this time;

[0024] The injection time of the foaming material is t, and the injection time t of the foaming material ranges from 0.1s to 3s.

[0025] The door panel structure, the electrical appliance and the foaming injection method provided by the application have the following beneficial effects:

[0026] In the application, the foaming material is a fluid with a certain viscosity. When it is injected into the metal sheet between the inner and outer metal sheets of the panel through a high-pressure foaming machine, if the thickness between the metal sheets is limited, the flow of the foaming material will be restricted, especially in the edge area of the panel. The thickness of the flow guide channel is greater than that of the foaming cavity, which provides a wider flow path for the foaming material, so that the foaming material can flow smoothly from the edge to the center area, thereby avoiding the formation of a foaming blind area. Through the flow guide channel, the foaming material can more uniformly fill the entire door panel structure, ensuring that the thickness and density of the foaming layer are uniform and consistent, which is crucial for the overall performance (such as strength, sealing performance, etc.) of the panel. The flow guide channel provides a low-resistance flow path for the foaming material, so that the foaming material can be filled into the foaming cavity more quickly, which not only reduces the injection time but also improves the production efficiency. During the foaming process, rapid and uniform filling can reduce the formation of bubbles and cavities, thereby improving the quality and performance of the foaming layer. The design of the flow guide channel can guide the flow direction of the foaming material, so that it fills the foaming cavity according to the predetermined path. This controllability helps to ensure the stability of the foaming process and reduce defects caused by uneven flow of the foaming material. By reasonably designing the shape and size of the flow guide channel, it can be applied to door panel structures of different shapes and sizes, improving the universality and flexibility of the process. Attached Figure Description

[0027] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0028] Figure 1 This is an exploded view of the door panel structure according to an embodiment of the present invention;

[0029] Figure 2 This is a partial cross-sectional view of the door panel structure according to an embodiment of the present invention;

[0030] Figure 3 This is a schematic diagram of the inner and outer steps according to an embodiment of the present invention;

[0031] Figure 4 This is a schematic diagram of the isolation component according to an embodiment of the present invention;

[0032] Figure 5 The door panel structure and side panel are connected in this embodiment of the invention;

[0033] Figure 6 This is a schematic diagram of the door panel structure dimensions according to an embodiment of the present invention;

[0034] Figure 7 This is a schematic diagram of the exhaust passage according to an embodiment of the present invention.

[0035] Attached Figures: 1-Inner Panel; 101-Inner Step; 2-Outer Panel; 201-Flanged Edge; 202-Outer Step; 203-Mounting Through Hole; 3-Foaming Material; 41-Flow Channel; 42-Foaming Cavity; 51-First Sealing Body; 52-Second Sealing Body; 53-Isolation Component; 531-U-shaped Sponge; 532-Long Strip Sponge; 6-Sealing Elastic Component; 7-Side Plate; 8-Locking Component. Detailed Implementation

[0036] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0037] In the description of the present application, it should be understood that the orientation words such as "front, back, up, down, left, right", "transverse, vertical, perpendicular, horizontal" and "top, bottom" and the like indicated orientation or position relationship are generally based on the orientation or position relationship shown in the drawings, only for the convenience of describing the present application and simplifying the description, without making the opposite statement, these orientation words do not indicate and imply that the indicated device or element must have a particular orientation or be constructed and operated in a particular orientation, therefore it cannot be understood as a limitation on the scope of protection of the present application; the orientation words "inner, outer" refer to the inner and outer of the contour of each component itself.

[0038] For the convenience of description, spatial relative terms such as "over", "above", "upper surface", "upper" and the like can be used herein to describe the spatial position relationship of one device or feature with other devices or features as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations in use or operation in addition to the orientation of the device described in the drawings. For example, if the device in the drawing is inverted, the device described as "above" or "over" other devices or structures will be positioned "below" or "under" other devices or structures.

[0039] For the convenience of description, spatial relative terms such as "over", "above", "upper surface", "upper" and the like can be used herein to describe the spatial position relationship of one device or feature with other devices or features as shown in the drawings. It should be understood that the spatial relative terms are intended to include different orientations in use or operation in addition to the orientation of the device described in the drawings. For example, if the device in the drawing is inverted, the device described as "above" or "over" other devices or structures will be positioned "below" or "under" other devices or structures. Figures 1 to 5 As shown, according to the embodiment of the present application, a door panel structure is provided, which comprises an inner panel 1 and an outer panel 2; the inner panel 1 is mounted on the outer panel 2, and the inner panel 1 and the outer panel 2 are filled with foaming material 3; a flow guide channel 41 is formed between the edge of the inner panel 1 and the edge of the outer panel 2, and the main body part of the inner panel 1 and the outer panel 2 forms a foaming cavity 42; the thickness of the flow guide channel 41 is greater than the thickness of the foaming cavity 42, so that the foaming material 3 flows from the edge to the central area during the foaming process.

[0040] It is worth noting that the outer panel 2 meeting the design requirements is manufactured by stamping sheet metal processing technology, the structure of which has been designed in advance, and the edge area will be used to form part of the flow guide channel 41; similarly, the inner panel 1 is manufactured by sheet metal processing, the design of which matches the outer panel 2, and the edge area is also designed accordingly to ensure that when the inner and outer panels 2 are assembled, a specific flow guide channel 41 can be formed at the edge, and a foaming cavity 42 can be formed at the main body part.

[0041] Specifically, the main body part of the inner panel 1 and the outer panel 2 forms a foaming cavity 42, which is the main area filled with foaming material 3, and the thickness needs to be designed according to product requirements. Install the inner panel 1 on the outer panel 2, and in this assembled state, the geometry of the foaming cavity 42 (main body part, smaller thickness) and the flow guide channel 41 (edge part, larger thickness) has been preliminarily formed. Align the injection head of the high-pressure foaming machine with one or several pre-set injection ports of the flow guide channel 41, and inject the mixed foaming material 3 under high pressure. Since the thickness of the flow guide channel 41 is greater than that of the foaming cavity 42, its resistance to the flow of foaming material 3 is much smaller than that of the foaming cavity 42. Therefore, the foaming material 3 will preferentially and quickly fill the entire edge flow guide channel 41, forming a complete annular flow. Under the combined action of the pressure of the foaming material 3 itself and the continuous injection pressure, this flow that has filled the flow guide channel 41 will simultaneously and uniformly advance to the central foaming cavity 42 area from the four edges of the panel. After the foaming material 3 is filled, the panel is stationary for a period of time to allow the foaming material 3 to complete the chemical reaction, expand to the final form and solidify to form a solid foaming layer. At this time, the foaming layer is tightly combined with the inner and outer panels 2, forming a firm metal-foaming-metal composite structure.

[0042] In this embodiment, the foaming material 3 is a fluid with a certain viscosity. When it is injected into the space between the inner and outer metal panels of the door panel through the high-pressure foaming machine, if the thickness between the metal panels is limited, the flow of the foaming material 3 will be restricted, especially in the edge area of the panel. The thickness of the flow guide channel 41 is greater than that of the foaming cavity 42, providing a wider flow path for the foaming material 3, allowing it to flow smoothly from the edge to the center area, thereby avoiding the formation of foaming blind areas. Through the flow guide channel 41, the foaming material 3 can more uniformly fill the entire door panel structure, ensuring that the thickness and density of the foaming layer are uniform, which is crucial for the overall performance of the panel (such as strength, sealing, etc.). The flow guide channel 41 provides a low-resistance flow path for the foaming material 3, allowing it to fill the foaming cavity 42 more quickly. This not only reduces the injection time, but also improves production efficiency. Rapid and uniform filling during the foaming process can reduce the formation of bubbles and cavities, thereby improving the quality and performance of the foaming layer. The design of the flow guide channel 41 can guide the flow direction of the foaming material 3, making it fill the foaming cavity 42 according to the predetermined path. This controllability helps to ensure the stability of the foaming process and reduces defects caused by uneven flow of the foaming material 3. By reasonably designing the shape and size of the flow guide channel 41, it can be applied to door panel structures of different shapes and sizes, improving the universality and flexibility of the process.

[0043] In this embodiment, in the conventional process, due to the limited thickness between the inner and outer panel sheet metal parts, the foaming material 3 is prone to form a foaming blind area around the edge during pouring, resulting in uneven foaming, affecting the overall performance of the panel. By setting a flow guide channel 41 between the edges of the inner panel 1 and the outer panel 2, and making the thickness of the flow guide channel 41 greater than the thickness of the foaming cavity 42, the foaming material 3 can flow smoothly from the edge to the center area during pouring, thereby effectively avoiding the formation of a foaming blind area and ensuring that the foaming material 3 can uniformly fill the entire door panel structure. The inner panel 1 and the outer panel 2 are both sheet metal parts, and the panel adopts a composite structure of sheet metal part-foaming layer-sheet metal part. The foaming layer can be tightly combined with the inner and outer sheet metal parts after solidification, forming a whole, thereby significantly enhancing the overall strength and rigidity of the panel. Compared with the traditional sponge paste structure, the solid structure formed by foaming is more solid and can better withstand external impact and stress during long-term use, prolonging the service life of the panel. The foaming material 3 can form a tight filling layer after solidification, which is tightly combined with the inner and outer sheet metal parts of the panel, thereby providing better sealing performance.

[0044] As a specific implementation, the foaming material 3 is preferably a polyurethane foaming material 3, and the heat preservation effect is 1.4 times that of the traditional sponge support structure panel. Among them, the ratio of isocyanate to combined polyether component in the polyurethane foaming material 3 is (1.05-1.3):1, that is, the weight of isocyanate is 1.05-1.3 times that of the combined polyether. The panel of this embodiment adopts a thinner sheet metal part design, and the foaming panel with a sheet metal part thickness of only 0.58mm can reach the strength of a traditional sponge support structure with a sheet metal part thickness of 1.45mm. Considering welding and other production factors, the thickness of the sheet metal part is preferably 0.75mm, and the second choice is 0.58-0.95mm other thickness sheet metal part. The foaming plate thickness of a conventional specification door panel structure (about 860mm*420mm) should be 15mm, otherwise there may be foaming not full or air bubbles. This embodiment can realize the thinnest 5~8mm foaming panel

[0045] For reference Figures 1 to 5As shown, the outer edge of the inner panel 1 is connected with the outer panel 2, and the connection here is that the outer edge of the inner panel 1 is in contact with the edge of the outer panel 2, and temporary fixing devices (such as clamps) can also be used to fix the inner panel 1 and the outer panel 2 together to prevent displacement during subsequent pouring. The outer edge of the inner panel 1 is bent inward to form an inner step 101 on the outer panel 2, that is, the main part of the inner panel 1 is a plane, and the outer edge part of the inner panel 1 is higher than the plane, thereby forming the inner step 101, and the inner step 101, the inner panel 1 and the outer panel 2 form a flow guide channel 41. In this embodiment, the longitudinal section of the door panel structure is taken as the projection plane, the top surface of the inner step 101 is in contact with the edge of the outer panel 2, and the bottom surface of the inner step 101 extends in the length direction of the inner panel 1, which is the main part of the inner panel 1, that is, the bottom surface of the inner step 101 and the inner wall of the outer panel 2 form a foaming cavity 42, and the top surface of the inner step 101 and the inner wall of the outer panel 2 form the flow guide channel 41.

[0046] Specifically, the inner panel 1 is placed on the outer panel 2, and the inner step 101 of the inner panel 1 is ensured to face the outer panel 2, and the inner step 101, the inner panel 1 and the outer panel 2 naturally form a flow guide channel 41. The foaming material 3 is poured from the edge of the panel, and due to the large thickness of the flow guide channel 41, the foaming material 3 can smoothly flow from the edge to the central area.

[0047] In this embodiment, by bending the inner panel 1 to form the inner step 101, the inner step 101 is arranged to form a stable composite structure between the inner panel 1 and the outer panel 2, and the foaming material 3 is tightly combined with the inner and outer panel after solidification, which significantly enhances the overall strength and rigidity of the panel. The design of the inner step 101 enables the inner panel 1 and the outer panel 2 to naturally align and closely contact during assembly, reducing the dependence on temporary fixing devices (such as clamps), thereby simplifying the process flow. The structural design of the inner step 101 makes the assembly process more efficient, reduces the rework rate caused by inaccurate alignment, and improves production efficiency. The design of the inner step 101 can optimize the structural design of the panel without sacrificing strength, making it more lightweight. By reasonably designing the shape and size of the inner step 101, it can be applied to door panel structures of different shapes and sizes, improving the universality and flexibility of the process.

[0048] For reference Figures 1 to 5 As shown, in the direction towards the center of the foaming cavity 42, the outer panel 2 is provided with a folded edge on the side facing the inner panel 1 in the thickness direction, the folded edge of the outer panel 2 is provided with a flange 201, the outer edge of the inner panel 1 is connected with the outer edge of the flange 201, the outer edge of the flange 201 is bent outward to form an outer step 202 away from the outer panel 2, and the inner step 101, the outer step 202, the inner panel 1 and the outer panel 2 form a flow guide channel 41.

[0049] Specifically, the inner step 101 and the outer step 202 are both convex compared to the main body part of the inner panel 1, the outer step 202 has a height of 6-10mm relative to the outer periphery of the outer panel 2, the inner step 101 has a height of 6-10mm relative to the main body part of the inner panel 1, but compared to the plane of the main body part of the inner panel 1, the thickness of the outer step 202 to the main body part of the inner panel 1 is still greater than the thickness of the inner step 101 to the main body part of the inner panel 1, and with the bottom surface of the outer panel 2 as the reference, for the direction pointing to the center of the foaming cavity 42, the distance between the outer step 202, the inner step 101, the main body part of the inner panel 1 and the outer panel bottom surface is gradually reduced, that is, the thickness is gradually reduced.

[0050] In this embodiment, the thickness of the outer step 202, the inner step 101 and the main body part of the inner panel 1 gradually decreases, forming a gradual flow guide channel 41, this design makes the foaming material 3 flow more naturally from the edge to the center during the pouring process, the flow resistance gradually decreases, thereby improving the filling efficiency of the foaming material 3, the outer step 202 and the inner step 101 respectively guide the flow of the foaming material 3 from different directions, this multi-path guiding action can more effectively avoid the phenomenon of stagnation or accumulation of the foaming material 3 during the flow process, ensuring that the foaming material 3 can be uniformly filled into the foaming cavity 42.

[0051] In this embodiment, the inner step 101 and the outer step 202 together form a more complex flow guide channel 41 structure. This double-layer flow guide channel 41 can provide a more spacious and multi-path flow space for the foaming material 3, the synergistic effect of the inner step 101 and the outer step 202 makes the foaming material 3 flow more smoothly from the edge to the center area during the pouring process, reducing the flow resistance, further improving the filling efficiency of the foaming material 3, and ensuring that the foaming material 3 can quickly and uniformly fill the entire foaming cavity 42. The inner step 101 and the outer step 202 respectively guide the flow of the foaming material 3 from the inner side and the outer side, this double guiding action can more effectively avoid the phenomenon of stagnation or accumulation of the foaming material 3 during the flow process, thereby ensuring that the filling of the foaming material 3 in the foaming cavity 42 is more uniform, through the synergistic effect of the inner step 101 and the outer step 202, the foaming material 3 can be more uniformly distributed in the entire door panel structure, further reducing the formation of foaming blind area, improving the quality and performance of the foaming layer. The setting of the inner step 101 and the outer step 202 makes the connection between the inner panel 1 and the outer panel 2 more closely, forming a more stable composite structure, this structure can better withstand external force impact and stress during long-term use, significantly enhancing the overall strength and rigidity of the panel.

[0052] It is worth mentioning that the inner step 101 and the outer step 202 jointly form a flow guide channel 41 structure, and the working principle of the faster glue filling speed is that the foaming material in the interlayer between the inner panel and the outer panel is approximately equivalent to the Poiseuille flow model under the laminar flow condition, and the velocity distribution along the height direction between the panels is parabolic

[0053]

[0054] In the formula, h is the panel spacing between the inner panel 1 and the outer panel 2; z is the thickness of the foaming cavity 42; μ is the viscosity of the foaming material; dp / dx is the pressure gradient along the flow direction, which can be considered as a constant value in the present panel structure, and the average velocity vavg can be calculated by integration:

[0055]

[0056] That is, the average filling speed is proportional to the square of the spacing between the inner panel 1 and the outer panel 2, so the filling speed at the edge of the stepped panel is much larger than the filling speed in the middle, which plays a role in guiding the flow. The design of the stepped surface greatly improves the filling speed at the edge, which can effectively avoid the problem of abnormal defective products caused by the accumulation of foaming material; at the same time, the inner concave design of the double stepped surface can also reduce the use amount of foaming material, and can increase the internal volume after the panel is assembled.

[0057] For reference Figure 6 In the present embodiment, the inner step 101 provides an efficient flow guide channel for the foaming material; the empirical filling speed of the foaming material is: ;

[0058] Wherein, k is the empirical filling coefficient, preferably in the range of 40-100; ρ is the corresponding foam density of the foaming material; μ is the viscosity value of the foaming material after mixing in Pa·s; V is the cavity volume of a single panel; H is the step parameter, which is the ratio of the average height h1 of the stepped surface to the panel height h2, that is, H=h1 / h2; and the matching filling speed A=200-1000g / s, the step height h1≥15mm, preferably 2~3*h2, the width C2 is as small as possible, which satisfies the bending, and the width C1≥15mm.

[0059] For reference Figures 1 to 5 As shown in the figure, there is a gap between the outer periphery of the inner panel 1 and the outer periphery of the flange 201, and a first sealing body 51 is arranged in the gap, the first sealing body 51 is annular, the material of the first sealing body 51 is air-permeable sponge, and the first sealing body 51 is used to prevent overflow between the inner panel 1 and the outer panel 2.

[0060] In the embodiment, the presence of the gap can cause the foaming material 3 to overflow, affecting the product quality, and the main role of the first sealing body 51 is to prevent the foaming material 3 from overflowing from the gap between the inner panel 1 and the outer panel 2 during the pouring process. Since the foaming material 3 has a certain fluidity and expansibility, if there is no sealing measure, the foaming material 3 can flow out of the door panel structure along the gap, polluting the equipment and the product, and even causing the product to be scrapped. Through the isolation effect of the first sealing body 51, the overflow of the foaming material 3 can be effectively avoided, the production site can be kept clean, and the cleaning work and material waste can be reduced.

[0061] In the embodiment, the material of the first sealing body 51 is air-permeable sponge. Although the air-permeable sponge allows gas to pass through, it can effectively block the flow of liquid (such as the foaming material 3). During the pouring process of the foaming material 3, the air-permeable sponge can prevent the foaming material 3 from overflowing from the gap between the inner panel 1 and the outer panel 2, while allowing air to be discharged from the gap. The blocking effect of the air-permeable sponge can avoid the overflow of the foaming material 3 to pollute the equipment and the surrounding environment, keep the production site clean, and reduce the cleaning work and material waste. The air permeability of the air-permeable sponge allows air to be discharged from the gap, avoiding the accumulation of air in the gap to form bubbles or cavities. This helps the foaming material 3 to fill the foaming cavity 42 more smoothly during the pouring process, reducing the problem of uneven filling caused by air accumulation. The air-permeable sponge can ensure that the foaming material 3 uniformly fills the entire cavity during the foaming process, improving the quality and performance of the foaming layer. The air permeability allows the foaming material 3 to better adapt to internal pressure changes during the curing process, reducing defects caused by uneven pressure. In addition, the air-permeable sponge can avoid the formation of excess parts of the foaming material 3 on the surface of the panel, thereby ensuring the surface quality of the product and improving the aesthetics of the product. The elastic sealing effect of the air-permeable sponge can ensure uniform curing of the foaming material 3, making the appearance of the entire panel more consistent and reducing appearance defects caused by overflow.

[0062] For reference Figures 1 to 5 As shown in the figure, the outer panel 2 is provided with a folded edge on the side facing the inner panel 1 in the thickness direction. For the inner wall of the outer panel 2, there is a corner area on the inner wall of the outer panel 2. The second sealing body 52 is arranged in the corner area, and the second sealing body 52 is located at the corner of the flow guide channel 41. The second sealing body 52 is used to prevent the foaming material 3 from leaking. The second sealing body 52 is also air-permeable sponge.

[0063] In this embodiment, the main function of the second sealing body 52 is to prevent the foaming material 3 from leaking from the corner area during the pouring process. Due to the complex space at the corner and the possible flow resistance, the foaming material 3 is prone to accumulate or leak at this point. The air-permeable sponge can effectively block the flow of the foaming material 3, ensuring that it remains in the flow channel 41 and the foaming cavity 42, preventing leakage. Not only does this avoid waste of the foaming material 3, but it also reduces the cleaning work and equipment pollution caused by leakage, improving production efficiency and economic benefits. The air-permeability of the air-permeable sponge allows air to be discharged from the corner area, thereby avoiding the accumulation of air at the corner to form bubbles or cavities. This helps the foaming material 3 to fill the entire foaming cavity 42 more smoothly, improving the uniformity of filling. While blocking the foaming material 3, the air-permeable sponge allows gas to be discharged, reducing the flow resistance of the foaming material 3 at the corner area, allowing the foaming material 3 to flow more smoothly into the flow channel 41 and the foaming cavity 42. The elasticity of the air-permeable sponge allows it to closely fit the inner wall of the corner area, providing good sealing effect. Even after the foaming material 3 solidifies, the air-permeable sponge still maintains a certain degree of elasticity, further enhancing the sealing performance.

[0064] In this embodiment, the first sealing body 51 (air-permeable sponge) is located in the outer peripheral gap between the inner panel 1 and the outer panel 2, mainly preventing the foaming material 3 from overflowing from the edge of the panel. The air-permeable sponge also prevents corner air trapping, while allowing air to be discharged. The second sealing body 52 provides a first sealing barrier for the foaming material 3; the second sealing body 52 (air-permeable sponge) is arranged at the corner area, especially at the corner of the flow channel 41, to prevent the foaming material 3 from leaking from the corner area. The second sealing body 52 provides a second sealing barrier for the foaming material 3, and through double sealing protection, the first sealing body 51 and the second sealing body 52 work together to ensure that the foaming material 3 does not leak outside the panel or accumulate in complex areas during the pouring process, thereby significantly improving the sealing effect. This double protection mechanism reduces pollution caused by leakage of the foaming material 3, maintains a clean production environment, and also reduces material waste. The air-permeability of the first sealing body 51 allows air to be discharged from the gap, reducing the problem of air accumulation causing bubbles or cavities, ensuring that the foaming material 3 can smoothly fill the foaming cavity 42. The air-permeability of the second sealing body 52 further optimizes the flow path of the foaming material 3 in the corner area, avoiding accumulation or flow resistance of the foaming material 3 in the complex corner area. The two work together to ensure that the foaming material 3 can uniformly fill the entire foaming cavity 42 during the foaming process, reducing the problem of uneven filling caused by poor flow. Uniform filling not only improves the quality of the foaming layer, but also reduces internal defects such as bubbles and cavities in the product.

[0065] For a more complete understanding of the present application, reference is made to the following description and appended claims taken in conjunction with the accompanying drawings. Figures 1 to 5As shown, the microstructure of the second sealing body 52 has interconnected pores to allow the second sealing body 52 to pass and discharge the gas generated during the foaming process. In other embodiments, the second sealing body 52 can also be a microporous silica gel with tiny interconnected pores that can allow the gas to pass through.

[0066] In this embodiment, a large amount of gas is generated during the foaming process, which needs to be discharged in time, otherwise it will form bubbles or cavities in the foaming layer, affecting the quality and performance of the foaming layer. The interconnected pores of the second sealing body 52 allow the gas to pass through and discharge smoothly, thereby optimizing the foaming process. By discharging the gas in time, the second sealing body 52 reduces the formation of bubbles and cavities in the foaming layer, ensuring the uniformity and density of the foaming layer.

[0067] For reference Figures 1 to 5 As shown, the outer panel 2 is provided with a mounting through hole 203 for mounting the display panel; the outer panel 2 is also provided with a spacer 53, which is arranged around the mounting through hole 203, and the spacer 53 is used to block the flow of the foaming material 3 to the mounting through hole 203.

[0068] Specifically, the second sealing body 52 (breathable sponge) is installed at the corner area, the spacer 53 is installed around the mounting through hole 203 to ensure that it can effectively block the flow of the foaming material 3 to the mounting through hole 203, the first sealing body 51 (breathable sponge) is installed in the gap between the inner panel 1 and the outer panel 2, and the inner panel 1 and the outer panel 2 are aligned to ensure that they are tightly attached. The inlet is provided on the wall of the outer panel 2 away from the mounting through hole 203, and the foaming material 3 is injected into the door panel structure through the nozzle using a high-pressure foaming machine. During the pouring process, the flow of the foaming material 3 is closely monitored to ensure that it is uniformly filled into the foaming cavity 42. Due to the presence of the spacer 53, the foaming material 3 is blocked outside the mounting through hole 203, ensuring that the mounting through hole 203 area remains clean and is not contaminated by the foaming material 3. During the solidification process, the foaming material 3 will expand and fill the entire foaming cavity 42, forming a solid structure. The display panel is installed at the mounting through hole 203 to ensure that it is firmly and tightly connected to the outer panel 2.

[0069] In this embodiment, the main role of the isolation piece 53 is to block the foaming material 3 from flowing into the mounting through hole 203. The mounting through hole 203 is usually used to mount the display panel or other critical components, which have high requirements for cleanliness and precision. The isolation piece 53 can prevent the foaming material 3 from entering these areas to avoid contamination and damage. Through the blocking effect of the isolation piece 53, the mounting through hole 203 area remains clean and dry, facilitating subsequent component installation and sealing process. The isolation piece 53 ensures that the foaming material 3 only fills into the predetermined foaming cavity 42 and flow guide channel 41 during the foaming process, avoiding the accumulation of foaming material 3 in unnecessary areas, thereby improving the uniformity and efficiency of filling. By precisely controlling the flow path of the foaming material 3, the isolation piece 53 reduces the waste of foaming material 3 and reduces production costs. The isolation piece 53 works together with the first sealing body 51 and the second sealing body 52 to provide multi-layer sealing protection for the door panel structure. The isolation piece 53 can prevent the foaming material 3 from leaking from the mounting through hole 203 during the solidification process, further enhancing the overall sealing performance of the panel. The isolation piece 53 still maintains its blocking effect after the foaming material 3 solidifies, ensuring that the panel will not affect the sealing performance due to the leakage of the foaming material 3 in long-term use. The design of the isolation piece 53 can be adjusted according to the specific structure of the panel and the position of the mounting through hole 203, making it adaptable to various complex panel designs. This flexibility makes the door panel structure more optimized, capable of meeting different product requirements. By precisely controlling the filling area of the foaming material 3, the isolation piece 53 helps to optimize the structural design of the panel, making it more lightweight without sacrificing strength and performance.

[0070] For reference Figures 1 to 5 As shown, the mounting through hole 203 is adjacent to the circumference of the outer panel 2, and the isolation piece 53 includes a U-shaped sponge 531 and a long strip sponge 532. The outer long side of the long strip sponge 532 abuts the inner side wall of the edge of the outer panel 2, and the two open ends of the U-shaped sponge 531 are connected to the two ends of the long strip sponge 532. The U-shaped sponge 531 preferably has a compression rate of 30%-40%.

[0071] Specifically, before assembling the inner panel 1 and the outer panel 2, the long strip sponge 532 is installed adjacent to the circumference of the outer panel 2, with its outer long side tightly fitted to the inner side wall of the edge of the outer panel 2. Then the U-shaped sponge 531 is arranged around the mounting through hole 203, with its two open ends connected to the two ends of the long strip sponge 532, forming a complete isolation structure. When pouring the foaming material 3, the isolation piece 53 can effectively block the foaming material 3 from flowing into the mounting through hole 203.

[0072] In this embodiment, the display screen mounting area is pre-divided by using U-shaped sponge 531 and long strip sponge 532, realizing pre-punching, without the need for additional removal of knock-off holes, improving production efficiency. The U-shaped sponge 531 is arranged around the mounting through hole 203 and can tightly fit the edge of the mounting through hole 203, forming a closed blocking area, effectively preventing the foaming material 3 from flowing into the mounting through hole 203. This is crucial for protecting the display panel or other components that need to be installed in the mounting through hole 203 later. It avoids installation difficulties or component damage caused by contamination of the foaming material 3. The long side of the long strip sponge 532 abuts the inner side wall of the edge of the outer panel 2, further enhancing the blocking effect. It is connected to both ends of the U-shaped sponge 531, forming a complete isolation structure, ensuring that the foaming material 3 will not leak from the edge of the mounting through hole 203 or the circumference of the outer panel 2. Through the arrangement of this isolation piece 53, the foaming material 3 is accurately guided into the foaming cavity 42 and the flow guide channel 41 during the pouring process, avoiding disordered flow and accumulation at the mounting through hole 203. This helps to improve the uniformity and efficiency of the foaming material 3 filling, reduces the formation of foaming blind areas, and ensures the quality and performance of the foaming layer. The combined structure of the U-shaped sponge 531 and the long strip sponge 532 can tightly fit the inner wall of the outer panel 2 and the edge of the mounting through hole 203, forming a multi-layer seal. During the curing process of the foaming material 3, this structure can effectively prevent the foaming material 3 from leaking from the gap between the isolation piece 53 and the outer panel 2, enhancing the overall sealing performance of the panel. Even after the foaming material 3 solidifies, the sponge material still maintains a certain elasticity, continuing to play a sealing role. This ensures that the panel will not affect the sealing performance due to leakage of the foaming material 3 during long-term use, prolonging the service life of the product.

[0073] In other embodiments, the design of this isolation piece 53 can be adjusted according to the specific position and shape of the mounting through hole 203, so that it can adapt to different door panel structures and installation requirements. For example, the size and shape of the U-shaped sponge 531 can be customized according to the size of the mounting through hole 203, and the length of the long strip sponge 532 can also be adjusted according to the circumference of the outer panel 2. By accurately controlling the filling area of the foaming material 3, this isolation piece 53 helps to optimize the structural design of the panel, making it more lightweight without sacrificing strength and performance.

[0074] For reference Figures 1 to 5 As shown in the figure, the inner panel 1 is provided with a sealing elastic piece 6 on the side edge facing away from the flow guide channel 41. Specifically, the inner panel 1 is provided with an inner step 101, and a first sealing body 51 is arranged between the outer circumferential inner wall of the inner panel 1 and the outer circumferential outer wall of the outer panel 2. The outer circumferential outer wall of the inner panel 1 is provided with a sealing elastic piece, which is a double-component glue formed by gluing. The sealing elastic piece 6 protrudes from the outer step 202, and the sealing elastic piece is deformed by elasticity to seal the inner panel 1 and the side panel 7.

[0075] Specifically, glue is applied on the outer edge wall of the inner panel 1, ensuring uniform coating of the glue, forming a sealing elastic member 6 (two-component glue) protruding from the outer step 202, with a height of 2-3 mm above the outer step 202 surface, so that subsequent elastic deformation can achieve sealing, and when the face door panel assembly is closed relative to the side panel 7, the sealing elastic glue abuts against the side panel 7. The sealing elastic member of the embodiment, in combination with the structural arrangement of the inner panel 1 and the outer panel 2, can reduce the panel assembly gap while ensuring sealing, reducing the panel assembly gap from the traditional panel of 8.67 mm to 2.94 mm, a decrease of 66.09%, improving the product aesthetics.

[0076] In this embodiment, the panel edge step structure combines the design of two-component glue elastomer, which ensures the sealing while improving the foaming filling rate and uniformity, reducing the panel assembly gap. The panel in this embodiment uses a foaming and gluing structure, and the material usage of the door panel assembly is greatly reduced from 38 to 14, the assembly is simpler and more efficient, and the cost is lower. When the door panel assembly is closed, the sealing elastic piece 6 (two-component glue) abuts against the side plate 7 and deforms elastically. This deformation allows the sealing elastic piece 6 to closely fit the surface of the side plate 7, even if there are small irregularities or defects on the surface of the side plate 7, the sealing effect can be achieved through elastic deformation. During the opening and closing process of the door panel assembly, the sealing elastic piece 6 can adapt to this dynamic change and maintain consistent sealing performance. This dynamic sealing is particularly important for panels that need to be frequently opened and closed (such as refrigerator doors, car doors, etc.), which can effectively prevent the entry of air, moisture or other pollutants. The sealing elastic piece 6, together with the first sealing body 51 (breathable sponge), the second sealing body 52 (breathable sponge) and the isolation piece 53, provides multi-layer sealing protection for the door panel structure. This multi-layer sealing design significantly improves the overall sealing performance of the panel, and even after long-term use, the sealing elastic piece 6 can still maintain good elasticity and continue to play a sealing role. This ensures that the panel will not be affected in performance due to sealing failure during long-term use, prolonging the service life of the product. Through close fitting with the side plate 7, the sealing elastic piece 6 further enhances the connection strength between the panel and the side plate 7, improving the structural stability of the entire door panel assembly. The sealing elastic piece 6 can reduce the dependence on additional sealing components (such as sealing strips, sealing pads, etc.), simplifying the structural design and assembly process of the door panel assembly. Through the stepped structure and the compression deformation of the sealing elastic piece 6, theoretically, zero gap can be achieved, and the panel sealing can be realized by using two-component glue and other elastomers. The traditional door seal panel has a defect that when placed horizontally for a period of time, due to the weight of the panel, the air between the door seal and the cooperating side plate is squeezed out, creating a vacuum. Under the action of atmospheric pressure, the panel will appear "sealed" phenomenon and be difficult to open. The panel in this embodiment uses a two-component glue elastomer seal with a semicircular cross-section. After the panel is closed, only a small part of the two-component glue is in direct contact with the side plate, which is equivalent to reducing the "surface contact" to "line contact", fundamentally avoiding the "sealed" phenomenon of the panel.

[0077] As a specific embodiment, the sealing elastic member is coated along the periphery and then rises, and the main components of the two-component glue are combined polyether and isocyanate, wherein the ratio of combined polyether to isocyanate is (4.5-7):1, that is, the weight of combined polyether is 4.5-7 times that of isocyanate; in addition to the two-component glue, EPDM foamed elastomer, EPDM solid elastomer, silicone rubber foamed elastomer and silicone rubber foamed elastomer can also be selected. It is worth noting that the traditional door seal needs to be riveted to the inner panel 1, which is complex to operate and wastes manpower, while the use of two-component glue can realize automatic gluing by machine, reduce the failure rate of personnel operation, improve product appearance, and reduce production cost. The gluing height of the two-component glue is a, wherein a1=30%~60%a, a1-a2-1~2mm is the height of the step h3, and 1~2mm is the gap between the inner panel 1 and the sponge.

[0078] For reference Figures 1 to 5 As shown, the inner panel 1 is provided with a locking piece 8 on the side facing away from the foaming cavity 42, and the locking piece 8 releasably connects the door panel structure and the side plate 7.

[0079] In this embodiment, the main function of the locking piece 8 is to firmly connect the door panel structure and the side plate 7 together. Through the mechanical locking action of the locking piece 8, the connection between the panel and the side plate 7 is more stable, and can withstand certain external impact and long-term stress in use. The design of the locking piece 8 usually considers sufficient strength and reliability to ensure that it will not loosen or fall off under normal use conditions. This releasable connection method is particularly suitable for door panel assemblies that need to be frequently opened and closed or maintained, such as refrigerator doors, car doors, electronic device housings, etc. The design of the locking piece 8 usually considers the convenience of user operation. Through simple push-pull, rotation or pressing actions, users can easily connect or separate the panel and the side plate 7. The mechanical locking action of the locking piece 8 can prevent the panel from accidentally loosening or falling off during use, improving the safety of the product.

[0080] As a specific embodiment, the locking piece 8 is a magnet bead collision locking device, providing mechanical locking force to fix the panel in the closed position; through the bead collision, the clear position feedback is provided to ensure the correct closing of the panel; and the sealing elastic piece cooperates to work, the strong locking force ensures that the sealing piece is fully compressed, so that the sealing effect is better than that of pure magnetic attraction. The magnet bead collision locking device includes a bead seat and a rolling bead fixed on the side plate 7, and an arc-shaped bracket fixedly installed on the inner panel 1, when the door panel assembly is closed, the rolling bead part of the bead first contacts and is pressed to be retracted, when the panel is about to be completely closed, the rolling bead is quickly clamped into the arc of the bracket under the joint action of the internal spring and the magnetic force, and the magnetic force provides additional adsorption force, so that higher locking force is generated. It can be understood that the way to realize the locking force enhancement and mechanical positioning is not limited to the magnet bead. For example, other mechanical locking structures such as a linear buckle, a T-shaped buckle, a spring pin buckle, and the like, which can provide a locking force better than pure magnetic attraction, should fall within the protection scope of the present application.

[0081] An electric appliance includes a cabinet and a door panel structure, the door panel structure is openably installed on the cabinet, and the door panel is the electric appliance described above. The electric appliance can be a water heater, a refrigerator, or the like, and any electric appliance requiring a door panel can adopt the door panel structure of the present embodiment.

[0082] For reference Figures 1 to 7 A foaming pouring method for pouring foaming material to the door panel structure, the door panel structure is the door panel structure described above, and the foaming method includes:

[0083] The door panel structure is placed in a limiting tool, the limiting tool includes an upper pressing plate, a stop block, a supporting plate, and a telescopic tool, a closed cavity is formed between the structures, the telescopic tool is a four-side sliding mechanism, the inner panel is raised by 5-7 face pads, so that the pressing force of the upper pressing plate can be effectively transmitted to the inner panel; the distance between the tool pressing surfaces is ≤100mm, and the thinner the thickness of the panel inner panel is, the smaller the size should be selected;

[0084] The outer panel 2 is provided with an installation through hole 203, and the inner panel 1 or the outer panel 2 is provided with a glue pouring hole, the foaming material 3 is injected from the glue pouring hole, the foaming material 3 flows into the flow guide channel 41, and the foaming material 3 continues to perform foaming reaction and gel reaction in the process of flowing, and the foaming material 3 completes the mixed milky white stage in the flow guide channel 41; specifically, the foaming material is mixed in a foaming machine by black material (mainly composed of isocyanate) and white material (mainly composed of combined polyether), then the foaming material in the mixed stage to the milky white stage is quickly poured into the panel cavity through a high-pressure foaming machine, and the foaming material 3 continues to perform foaming reaction and gel reaction while quickly filling the internal cavity of the panel through the stepped flow guide structure.

[0085] The foaming material 3 flows from the four sides to the foaming cavity 42, a parabolic exhaust passage is formed between the flow guide passage 41, the foaming cavity 42 and the mounting through hole 203, the gas in the foaming material 3 flows out from the mounting through hole 203, and the foaming material 3 completes the milky white swelling stage in the process of flowing in the exhaust passage. Specifically, the flow speed of the foaming material gradually decreases after entering the panel cavity from the pouring hole, thereby causing the panel cavity to be filled in a gradient manner, and the filling sequence is shown in the figure (the length of the arrow indicates the speed of filling), and due to the difference in filling speed, a parabolic exhaust passage is formed from the pouring hole to the display screen mounting area, and the gas is continuously exhausted from the U-shaped sponge; as the reaction proceeds, the exhaust passage is gradually filled with the foaming material, and by the time the rising time (the time from the start to the highest point of the foam), the panel cavity is filled with the foaming material, the foaming material is filled more uniformly, and the problem of insufficient foaming at the corners is solved.

[0086] As a specific embodiment, the foaming and glue pouring method further includes that after pouring is completed, the panel needs to be stationary for 80-120s (this time includes the reaction and filling of the foaming material in the panel), the foaming material undergoes the processes of mixing, milky white, foaming, swelling and gel curing, the molecules are cross-linked to form a network structure, the foam changes from a liquid state to an elastic gel state and no longer flows; the curing stage: after the two-component glue coating is completed, the panel needs to be in a pressed state for more than 3min, and then moved to other platforms for stationary for 3-20min, so that the internal foaming material is completely cured and the stability is improved.

[0087] For reference Figures 1 to 7 The raw materials of the foaming material 3 are isocyanate and combined polyether, wherein the mass of the isocyanate is M1, the mass of the combined polyether is M2, and M1:M2=(1.05-1.3):1;

[0088] The mixing time of the isocyanate and the combined polyether in the foaming machine is t1, and the mixing time t1≤4s, and the foaming material 3 is poured into the door panel structure through a spray gun;

[0089] The milky white time of the foaming material 3 is t2, the milky white time t2 is in the range of 6-8s, and the pouring speed is in the range of 200-1000g / s, and in this time, the foaming material 3 is poured into the flow guide passage 41; it is worth noting that in this time, the foaming material can basically complete the filling of most of the flow guide passage 41 (more than 60~80% of the area).

[0090] The pouring time of the foaming material 3 is t, and the foaming material pouring time t is in the range of 0.1-3s. Specifically, the value for a specific specification panel can be calculated by the following formula: ;

[0091] Wherein, α is the perfusion time coefficient, considering the influence of catalyst, foaming agent and other factors, α is 1.05-1.15; ρ is the foam density corresponding to the foaming material; V is the single panel cavity volume; A is the foaming material perfusion speed.

[0092] In the embodiment, the matching of the control basic parameters and the foaming perfusion parameters, the optimal volume dosage, and the control of the appropriate foaming material 3 dosage are controlled.

[0093] Those skilled in the art can easily understand that the above-mentioned advantageous modes can be freely combined and superimposed without conflict.

[0094] The above is only the preferred embodiment of the present application, and should not be construed as limiting the present application. Any modification, equivalent replacement and improvement within the spirit and principle of the present application shall be included in the protection scope of the present application. The above is only the preferred embodiment of the present application, and should not be construed as limiting the present application. Any modification, equivalent replacement and improvement within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A door panel structure, characterized in that, include: Inner panel (1) and outer panel (2); The inner panel (1) is mounted on the outer panel (2), and foam material (3) is filled between the inner panel (1) and the outer panel (2). A flow channel (41) is formed between the edge of the inner panel (1) and the edge of the outer panel (2), and a foam cavity (42) is formed in the main body of the inner panel (1) and the outer panel (2). The thickness of the flow channel (41) is greater than the thickness of the foaming cavity (42) so that the foaming material (3) flows from the edge of the panel to the center area during the foaming process.

2. The door panel structure according to claim 1, characterized in that, The outer periphery of the inner panel (1) is connected to the outer panel (2). The inner side of the outer periphery of the inner panel (1) bends toward the outer panel (2) to form an inner step (101). The guide channel (41) is formed between the inner step (101), the inner panel (1), and the outer panel (2).

3. The door panel structure according to claim 2, characterized in that, Oriented toward the center of the foaming cavity (42), the outer panel (2) is provided with a flange (201), the outer periphery of the inner panel (1) is connected to the outer periphery of the flange (201), the outer periphery of the flange (201) is bent away from the outer panel (2) to form an outer step (202), and the guide channel (41) is formed between the inner step (101), the outer step (202), the inner panel (1) and the outer panel (2).

4. The door panel structure according to claim 3, characterized in that, There is a gap between the outer periphery of the inner panel (1) and the outer periphery of the flange (201), and a first sealing body (51) is provided in the gap. The first sealing body (51) is used to prevent material from overflowing between the inner panel (1) and the outer panel (2).

5. The door panel structure according to claim 1, characterized in that, The inner wall corner area of ​​the outer panel (2) is provided with a second sealing body (52), and the second sealing body (52) is located at the corner of the flow channel (41). The second sealing body (52) is used to prevent the foam material (3) from leaking.

6. The door panel structure according to claim 5, characterized in that, The microstructure of the second sealing body (52) has interconnected pores so that the gas generated during the foaming process can pass through and be discharged.

7. The door panel structure according to claim 1, characterized in that, The outer panel (2) is provided with a mounting through hole (203) for mounting a display panel; the outer panel (2) is also provided with an isolation member (53) which surrounds the mounting through hole (203) and is used to prevent the foaming material (3) from flowing to the mounting through hole (203).

8. The door panel structure according to claim 7, characterized in that, The mounting through hole (203) is located near the periphery of the outer panel (2). The isolation member (53) includes a U-shaped sponge (531) and a long strip sponge (532). The outer long side of the long strip sponge (532) abuts against the inner sidewall of the edge of the outer panel (2). The two open ends of the U-shaped sponge (531) are respectively connected to the two ends of the long strip sponge (532).

9. The door panel structure according to claim 1, characterized in that, A sealing elastic element (6) is provided on the side edge of the inner panel (1) facing away from the flow channel (41). The sealing elastic element (6) seals the inner panel (1) with the side panel (7) through elastic deformation. The inner panel (1) is provided with a fastener (8) on the side facing away from the foam cavity (42), and the fastener (8) releasably connects the door panel structure to the side panel (7).

10. An electrical appliance, comprising a housing and a door panel structure, the door panel structure being closably mounted on the housing, characterized in that, The door panel structure is the door panel structure according to any one of claims 1 to 9.

11. A foaming injection method for injecting foaming material into a door panel structure, characterized in that, The door panel structure is the door panel structure according to any one of claims 1 to 9, and the foaming method includes: The door panel structure is placed in the limiting fixture; The outer panel (2) is provided with an installation through hole (203), and the inner panel (1) or the outer panel (2) is provided with a glue-filling hole. The foaming material (3) is injected from the glue-filling hole and flows into the guide channel (41). During the flow of the foaming material (3), the foaming reaction and gelation reaction continue to occur. The foaming material (3) completes the mixing milky white stage in the guide channel (41). The foaming material (3) flows from all sides into the foaming cavity (42). A parabolic exhaust channel is formed between the guide channel (41), the foaming cavity (42), and the mounting through hole (203). The gas in the foaming material (3) during its flow is discharged from the mounting through hole (203). The foaming material (3) completes the milky expansion stage during its flow in the exhaust channel.

12. The foaming and infusion method according to claim 11, characterized in that, The raw materials of the foaming material (3) are isocyanate and polyether, wherein the mass of the isocyanate is M1 and the mass of the polyether is M2, and M1:M2=(1.05-1.3):1; The mixing time of the isocyanate and the combined polyether in the foaming machine is t1, the mixing time t1≤4s, and the foaming material (3) is injected into the door panel structure through a spray gun; The milky white time of the foaming material (3) is t2, the range of the milky white time t2 is 6-8s, the range of the pouring speed is 200-1000g / s, and the foaming material (3) is poured into the guide channel (41) within this time. The injection time of the foaming material (3) is t, and the range of the injection time t is 0.1-3s.

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