Modeling door plate and preparation method thereof

Abstract

The invention relates to the technical field of buildings, in particular to a modeling door plate and a preparation method thereof. The manufacturing method of the modeling door plate comprises the following steps that a mold is provided, the mold is provided with a groove, and the inner wall of the groove is provided with a preset model; the groove is filled with a shell material, the shell material is cured to form a shell, and the shell comprises a modeling face and a back face which are opposite to each other; and a plate is bonded to the back face of the shell, compression molding is conducted, and the modeling door plate is prepared. The modeling door plate manufacturing process can be simplified, the machining cycle time is shortened, material loss is reduced, high-complexity curved surface or three-dimensional texture modeling can be achieved, the process stability is good, and the yield is high.

Description

Technical Field

[0001] This application relates to the field of building technology, and in particular to shaped door panels and their preparation methods. Background Technology

[0002] When manufacturing door panels, surface shaping is usually required to enhance their aesthetic value and decorative effect. Traditional methods for shaping wooden door panels rely on machining, such as milling, drilling, and carving, to create pre-defined patterns or outlines on the panel substrate to form the basic shape. These methods have the following problems: 1) Milling complex shapes is time-consuming, taking several days; 2) Machining results in significant material waste; 3) Milling leads to deformation and cracking, poor process stability, and a high defect rate; 4) It is difficult to achieve highly complex, curved, or three-dimensional texture designs, and relying on external suppliers compromises the flexibility of independent design. Summary of the Invention

[0003] Based on this, the first aspect of this application provides a shaped door panel, the technical solution of which is as follows:

[0004] A method for preparing a decorative door panel includes the following steps:

[0005] A mold is provided, the mold having a groove, the inner wall of the groove having a preset shape;

[0006] The outer shell material is filled into the groove and cured to form an outer shell, which includes opposing shaped surfaces and a back surface;

[0007] A sheet material is bonded to the back of the outer shell and pressed to form the shaped door panel.

[0008] In some embodiments, the housing material includes a polymer resin, fillers, and reinforcing fibers.

[0009] In some embodiments, the reinforcing fiber is selected from glass mat, which has at least two layers. Filling the groove with the outer shell material includes the following steps:

[0010] The filler and a portion of the polymer resin are mixed to obtain a resin solution;

[0011] The resin liquid is filled into the groove, and then the glass mat is laid. The remaining polymer resin is coated between two adjacent layers of glass mat.

[0012] In some embodiments, the polymer resin includes an unsaturated polyester resin.

[0013] In some embodiments, the filler is selected from at least one of perlite and calcium carbonate.

[0014] In some embodiments, the perlite has a mesh size of 70 to 90 mesh.

[0015] In some embodiments, the calcium carbonate has a mesh size of 800 to 1200 mesh.

[0016] In some embodiments, the perlite is in the form of 3 to 8 parts by weight.

[0017] In some embodiments, the calcium carbonate is 30 to 40 parts by weight.

[0018] In some embodiments, the polymer resin is 35 to 45 parts by weight; the filler is 35 to 45 parts by weight; and the reinforcing fiber is 5 to 8 parts by weight.

[0019] In some embodiments, the following steps are included before filling the recess with the housing material:

[0020] A protective material is coated onto the inner wall of the groove and cured to form a protective layer covering the inner wall.

[0021] In some embodiments, the material of the board includes wood, which includes at least one of artificial wood and natural wood.

[0022] In some embodiments, an adhesive is used to bond a sheet to the back of the housing; the adhesive includes a polymer resin, perlite, and sand powder.

[0023] The second aspect of this application provides a shaped door panel, which is manufactured by the preparation method described above.

[0024] Compared with traditional solutions, this application has the following advantages:

[0025] This application provides a novel method for manufacturing shaped door panels. The method utilizes a mold with a pre-designed shape to form a split outer shell with a corresponding shape. The outer shell is then bonded to a sheet material and pressed to obtain the shaped door panel. This method eliminates the need for traditional machining steps such as cutting, milling, and drilling, overcoming the complexity of sheet material shaping processes, simplifying the manufacturing process, enabling rapid door panel forming, shortening processing time, reducing material waste, saving labor costs, increasing production efficiency, and allowing for rapid mass production of door panel products that combine structural strength, decoration, and functionality. Furthermore, it can achieve highly complex, curved, or three-dimensional textured shapes, with good process stability and a high yield rate. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application and to more completely understand this application and its beneficial effects, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 One embodiment of the method for preparing a shaped door panel;

[0028] Figure 2 A schematic diagram of the mold structure for one implementation method;

[0029] Figure 3 This is a schematic diagram of the structure of the mold and the outer shell in one embodiment. Detailed Implementation

[0030] The present application will be further described in detail below with reference to specific embodiments. The present application can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of the disclosure of this application.

[0031] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0032] Unless otherwise stated or in case of contradiction, the terms or phrases used herein shall have the following meanings:

[0033] In this application, the terms "multiple", "various", "multiple times", "multi-dimensional", etc., unless otherwise specified, refer to a quantity greater than or equal to 2. For example, "one or more" means one or more or more.

[0034] In this application, "several" means at least one, such as one, two, etc., unless otherwise expressly and specifically defined.

[0035] In this application, the terms "optionally," "optionally," and "optional" refer to options that are optional, meaning they can be selected from either "with" or "without." If multiple "optional" options appear in a technical solution, unless otherwise specified and there are no contradictions or mutual constraints, each "optional" option is independent.

[0036] In this application, the terms "first aspect," "second aspect," "third aspect," and "fourth aspect," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or quantity, nor should they be construed as implicitly indicating the importance or quantity of the indicated technical features. Moreover, "first," "second," "third," and "fourth," etc., serve only a non-exhaustive enumeration purpose and should be understood not to constitute a closed limitation on quantity.

[0037] In this application, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0038] In this application, when an element is referred to as "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. It should also be understood that, in interpreting the connection or positional relationship of elements, although not explicitly described, connection and positional relationships are interpreted to include a range of error, which should be within the acceptable deviation range of a specific value as determined by a person skilled in the art.

[0039] In this application, numerical intervals (i.e. numerical ranges) are involved. Unless otherwise specified, the selected numerical distributions within the above-mentioned numerical intervals are considered continuous, and include the two numerical endpoints (i.e., the minimum value and the maximum value) of the numerical range, as well as every value between the two numerical endpoints.

[0040] In this application, room temperature refers to 10℃~40℃.

[0041] The first aspect of this application provides a method for manufacturing a shaped door panel. In one embodiment, please refer to... Figure 1 The preparation method of the shaped door panel includes the following steps:

[0042] S1. Provide molds, please refer to [link / reference]. Figure 2 The mold 10 has a groove 11, and the inner wall 11A of the groove has a preset shape.

[0043] The design of the inner wall of the groove can be customized according to the design requirements of the door panel. This can include complex structural shapes, curved surfaces, or three-dimensional textures. In this embodiment, the preset design is a three-dimensional texture.

[0044] In this embodiment, the dimensions of the mold groove can be designed according to the dimensions of the shaped door panel so that a shaped door panel of the required size can be obtained after demolding.

[0045] S2. Fill the groove with the shell material and cure it to form a shell, the shell including a shaped surface and a back surface.

[0046] Optionally, before filling the recess with the outer casing material, the following steps are included:

[0047] A protective material is coated onto the inner wall of the groove and cured to form a protective layer covering the inner wall.

[0048] Optionally, the protective material includes polyethylene (PE) resin. In this embodiment, the protective material includes a PE series hand primer, such as GEJ 199660 SCT INEOS white product gelcoat. When using, the PE series hand primer and thinner can be mixed at a mass ratio of 1:(0.1~0.5) and stirred thoroughly. For example, the PE series hand primer and thinner can be mixed at mass ratios of 1:0.1, 1:0.18, 1:0.28, 1:0.38, and 1:0.5. In this embodiment, the protective material is applied by spraying. Specifically, a thin layer is evenly sprayed along the inner wall of the groove using an airless spraying device to cover the inner wall of the groove, forming a continuous protective film. Optionally, the coating amount of the protective material is 250 g / m². 2 ~270g / m 2 For example, it can be 250g / m 2 260g / m 2 270g / m 2 After coating, allow it to cure for 20-30 minutes in a well-ventilated environment until the paint film reaches a touch-dry state (i.e., it is not sticky to the touch and leaves no marks), thus obtaining a protective layer. After demolding, the resulting protective layer can also be used as a primer layer, saving a subsequent painting step.

[0049] After forming a protective layer on the inner wall of the groove, the outer shell material is filled into the groove. Optionally, the outer shell material includes a polymer resin, a filler, and reinforcing fibers. Optionally, the polymer resin has a weight ratio of 35 to 45 parts, for example, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, or 45 parts. The filler has a weight ratio of 35 to 45 parts, for example, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, or 45 parts. The reinforcing fibers have a weight ratio of 5 to 8 parts, for example, 5, 6, 7, or 8 parts.

[0050] The polymer resin includes an unsaturated polyester resin. In this embodiment, the unsaturated polyester resin is AROPOL SS 68500. The main function of the unsaturated polyester resin is to provide adhesion. The filler is selected from at least one of perlite and calcium carbonate. The perlite can be closed-cell perlite. The perlite includes 70wt%~75wt% silica and 12wt%~15wt% alumina. For example, the perlite includes 70wt%, 71wt%, 72wt%, 73wt%, 74wt%, and 75wt% silica, and 12wt%, 13wt%, 14wt%, and 15wt% alumina. The perlite has a mesh size of 70 to 90 mesh. For example, the perlite has mesh sizes of 70, 80, and 90 mesh. The main function of the perlite is to reduce the weight of the outer shell, achieving lightweighting. The calcium carbonate has a mesh size of 800 to 1200 mesh. For example, the mesh size of calcium carbonate is 800 mesh, 900 mesh, 1000 mesh, 1100 mesh, or 1200 mesh. The main function of calcium carbonate is to achieve dense filling. Optionally, the perlite is 3 to 8 parts by weight, for example, 3, 4, 5, 6, 7, or 8 parts by weight. The calcium carbonate is 30 to 40 parts by weight, for example, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40 parts by weight. It is understood that the above-mentioned weight parts of perlite and calcium carbonate are relative to the 35 to 45 parts by weight of the polymer resin.

[0051] Optionally, the reinforcing fiber is selected from glass mat, and more preferably from chopped strand mat. In this embodiment, chopped strand mat of model HMC300-1040-E is used. The main function of the glass mat is to enhance the hardness and toughness of the outer shell. The glass mat has at least two layers. Filling the groove with the outer shell material includes the following steps:

[0052] S11, mixed filler and a portion of polymer resin, to obtain resin liquid.

[0053] Optionally, after mixing the filler and a portion of the polymer resin, mechanical stirring is performed at a speed ≤200 rpm to obtain a resin solution.

[0054] S12. The resin liquid is filled into the groove, and then the glass mat is laid. The remaining polymer resin is coated between two adjacent layers of glass mat.

[0055] The resin liquid can be poured into the groove. Due to its fluidity, the resin liquid can fill the pre-designed shape on the inner wall of the groove. Optionally, the time for pouring the resin liquid into the groove is 8 to 14 minutes. In this embodiment, after pouring the resin liquid, a bristle brush is used to apply multiple cross-brushes to the pre-designed area of ​​the groove, focusing on eliminating gaps at corners. In this embodiment, three cross-brushes are applied to the pre-designed area of ​​the groove to ensure that the resin liquid fully penetrates the pre-designed position. After pouring the resin liquid, glass mat is laid, with at least two layers. Each layer of glass mat is coated with polymer resin, bonding the two adjacent layers together. In this embodiment, each layer of glass mat is applied with a bristle brush to apply polymer resin, removing air bubbles between layers to ensure complete adhesion between the glass mats. Laying glass mat helps improve the hardness and toughness of the outer shell.

[0056] After the outer shell material is filled into the groove, it is left to cure at room temperature for 15 to 25 minutes. After curing, the resulting shell has a shaped surface on one side, and the opposite side is the back surface, which is flat. Please refer to [link / reference]. Figure 3 This is a schematic diagram of the structure of the outer shell and the mold in this embodiment. The outer shell has a shaped surface 21 and a back surface 22. The shaped surface 21 is formed by the inner wall of a groove with a preset shape, and the back surface is opposite to the shaped surface 21.

[0057] In this embodiment, after the outer shell has solidified, it is demolded. The back of the demolded outer shell is then sanded, and any excess chopped strand mat extending beyond the shell is removed. During sanding, a sander can be used to smooth the back of the outer shell; in this embodiment, a 60-grit grinding wheel is used. After sanding, filler can be applied, and any excess material on the outer shell can be further removed.

[0058] S3. Adhere the sheet material to the back of the outer shell, press and mold it to prepare the shaped door panel.

[0059] Optionally, the material of the board includes wood, and the wood includes at least one of artificial wood and natural wood. In this embodiment, the board is a multi-layer board.

[0060] Before attaching the sheet material to the back of the outer shell, the process includes cutting and sizing the raw sheet material. Optionally, the raw sheet material is cut and sized such that the side lengths of the large surface of the sheet material are reduced by 2mm to 4mm relative to the side lengths of the large surface of the finished shaped door panel. For example, the side lengths of the large surface of the sheet material are reduced by 2mm, 3mm, or 4mm. The large surface of the sheet material refers to the surface perpendicular to the thickness direction of the sheet material. By reducing the side length of the large surface of the sheet material, the sheet material can be inserted into the groove of the mold, allowing both the large surface and the sides of the sheet material to connect with the outer shell. In this embodiment, the dimensions of the sheet material are 2440mm × 1220mm × 12mm (length × width × height).

[0061] Optionally, the board has a first large surface, wherein the surface of the first large surface is sanded. The first large surface is bonded to the back of the outer casing. In this embodiment, the first large surface is a sanded engineered wood veneer, and the second large surface has a white melamine finish.

[0062] Optionally, an adhesive is used to bond a sheet material to the back of the housing. The adhesive comprises a polymer resin, perlite, and sand powder. Optionally, the polymer resin is present in parts by weight of 30 to 40, for example, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40. The perlite is present in parts by weight of 5 to 8, for example, 5, 6, 7, or 8. The sand powder is present in parts by weight of 30 to 40, for example, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40. The polymer resin includes unsaturated polyester resin. In this embodiment, the unsaturated polyester resin is AROPOL SS 68500. The main function of the unsaturated polyester resin is to provide adhesive strength. The perlite can be closed-cell perlite. Perlite comprises 70wt%~75wt% silica and 12wt%~15wt% alumina. For example, the perlite may comprise 70wt%, 71wt%, 72wt%, 73wt%, 74wt%, or 75wt% silica and 12wt%, 13wt%, 14wt%, or 15wt% alumina. The mesh size of the perlite is 70-90 mesh. For example, perlite may have mesh sizes of 70, 80, or 90 mesh. The main function of perlite is to reduce the weight of the decorative door panel. The sand powder can be 700-900 mesh pure white fine sand powder. For example, the fine sand powder may have mesh sizes of 700, 800, or 900 mesh.

[0063] In this embodiment, the step of bonding the sheet material to the back of the outer shell can be performed in the groove of the mold. The outer shell after the back is polished is placed back into the groove, the adhesive is applied to the back of the outer shell, and then the first large surface of the sheet material is placed in the groove with the back of the outer shell facing it. The material is then pressed and molded to obtain the shaped door panel.

[0064] During pressing, the bonded sheet and shell are fixed using a panel. The panel is placed on a horizontal calibration platform and subjected to balanced pressure in four directions using F-type clamps, ensuring uniform force on the sheet and shell. The clamping distance is ≤300mm. Two sets of bonded sheet and shell can be fixed with a panel at a time to prevent uneven stress. During pressing, material is squeezed out; the overflow amount is controlled to extend at least 2mm along the edge. The pressing time starts from the beginning of polymer resin gelation and lasts at least 2 hours. When the temperature difference between the sheet and the ambient temperature is ≤3℃, the constraints are released, and the sheet is demolded. After demolding, a sander (120# sandpaper) can be used to remove overflow material, cut off any excess chopped felt extending beyond the shaped door panel, and remove burrs. Sanding includes coarse and fine sanding. A primer can be applied before or after coarse sanding, and a topcoat can be applied after fine sanding. In this embodiment, the molded surface of the product after demolding is the front, and the opposite surface is the back. After demolding, the product is sanded with wood, then putty is applied, and after puttingty is applied, both the front and the molded surface are coated with UV primer. After forming a UV primer layer, the product is coarsely sanded. After coarsely sanding, the front is coated with UV primer, and after forming a UV primer layer, the product is finely sanded. After fine sanding, the front is coated with hand-applied topcoat to obtain the molded panel.

[0065] The finished door panels need to be laid flat on a pallet to prevent them from deforming, and then processed in the next step.

[0066] The above embodiments provide a novel method for preparing shaped door panels. This method utilizes a mold with a pre-designed shape to form a split outer shell with a corresponding shape. The outer shell is then bonded to a sheet material and pressed to obtain the shaped door panel. This method eliminates the need for traditional machining steps such as cutting, milling, and drilling, overcoming the complexity of sheet material shaping processes, simplifying the manufacturing process, enabling rapid door panel forming, shortening processing time, reducing material waste, saving labor costs, increasing production efficiency, and allowing for rapid mass production of door panel products that combine structural strength, decoration, and functionality. Furthermore, it can achieve highly complex, curved, or three-dimensional textured shapes, with good process stability and a high yield rate.

[0067] Compared to machining multi-layer boards using three-axis CNC machine tools to create shapes through milling and drilling, followed by manual sanding and painting for surface treatment, the above implementation method simplifies the manufacturing process. Compared to directly purchasing pre-made door panels (such as PVC-coated or solid wood carved panels), this method achieves complex shapes without relying on an external supply chain, resulting in lower costs. Compared to the time-consuming and multi-step process of milling complex shapes, requiring up to 5 days per piece, this method uses single-piece casting, eliminating the need for secondary painting and reducing the time per piece to 8-12 hours. Compared to the material waste from machining, milling scrap, and paint waste, this method uses precise proportioning and casting, resulting in a near-zero scrap rate. Compared to machining costs accounting for over 50% of total costs, this method saves on machining and labor costs, reducing overall costs by 30-40%. Limited by tool paths and board strength, traditional machining can only achieve low to medium complexity shapes; this method supports high complexity, curved surfaces, and three-dimensional textures in a single molding process. Compared to traditional machining methods that are prone to deformation and cracking, and have large process fluctuations, this implementation method features a seamless, one-piece structure with strong resistance to deformation, resulting in a yield rate increase of over 20%.

[0068] The second aspect of this application provides a shaped door panel, which is manufactured by the preparation method described above.

[0069] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0070] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method of manufacturing a shaped door panel, characterized in that, The method comprises the following steps: providing a mold having a groove, the inner wall of the groove having a preset molding; filling a shell material into the groove, and curing to form a shell, the shell comprising opposite molding surfaces and a back surface; bonding a board material to the back surface of the shell, and compression molding to prepare the molding door plate.

2. The method of claim 1, wherein the molding of the door panel is performed by a process comprising the steps of: The shell material comprises a polymer resin, a filler, and a reinforcing fiber. ​ 3. The method of claim 2, wherein the molding of the door panel is performed by a process comprising the steps of: The reinforcing fiber is selected from glass mat, and the number of layers of the glass mat is at least two. ​ The method for filling the shell material into the groove comprises the following steps: mixing the filler and a part of the polymer resin to obtain a resin liquid; 4. The method of claim 2, wherein the molding of the door panel is performed by a process of injection molding. filling the resin liquid into the groove, and then laying the glass mat, and coating the remaining part of the polymer resin between two adjacent layers of the glass mat. At least one of the following features is included: (1) the polymer resin comprises unsaturated polyester resin; 5. The method of claim 4, wherein the molding of the door panel is performed by a process comprising the steps of: (2) the filler is selected from at least one of perlite and calcium carbonate. ​ At least one of the following features is included: (1) the mesh number of the perlite is 70-90; (2) the mesh number of the calcium carbonate is 800-1200; (3) the weight fraction of the perlite is 3-8; 6. The method of claim 2, wherein the molding of the door panel is performed by a process comprising the steps of: (4) the weight fraction of the calcium carbonate is 30-40. ​ 7. The method of claim 1 to 6, wherein The weight fraction of the polymer resin is 35-45, the weight fraction of the filler is 35-45, and the weight fraction of the reinforcing fiber is 5-8. Before filling the shell material into the groove, the following steps are included:

8. The method of claim 1 to 6, wherein coating a protective material on the inner wall of the groove, and curing to form a protective layer covering the inner wall.

9. The method of claim 1 to 6, wherein The material of the board material comprises wood, and the wood comprises at least one of artificial wood and natural wood.

10. A shaped door panel characterized by, The board material is bonded to the back surface of the shell by using an adhesive, and the adhesive comprises a polymer resin, perlite, and sand powder. The molding door plate is prepared by the preparation method of any one of claims 1-9.

Images