Thermal connection module assembly suitable for sterile room and assembling method of thermal connection module assembly

Abstract

The invention discloses a thermal connection module assembly suitable for a sterile room and an assembling method. The thermal connection module assembly comprises at least two assemblies. Each of the components includes at least one core layer. The core layer has at least one side and at least one outer surface. An interlocking mechanism is arranged on the side face of the core layer and used for enabling any two adjacent assemblies to be connected with each other. The engagement surface of the interlocking mechanism, and / or the engagement side of each of the components, is covered with at least one layer of thermoformed material. And when the joint part of the connected interlocking mechanism is heated to enable the temperature of the thermoforming material to exceed the vicat softening point of the thermoforming material, the molten thermoforming material forms a continuous sealing layer at the joint part. The modular assembly system provided by the invention has remarkable advantages in aesthetic, functional, structural and sanitary dimensions. The invention further provides an assembling method.

Description

TECHNICAL FIELD

[0001] The present invention belongs to the technical field of panel, in particular to a hot connection module assembly suitable for aseptic room and an assembling method thereof. BACKGROUND

[0002] Currently, home customization has become a trend. Some components are used in home customization to assemble the required cabinets, tables, etc. Furniture components, such as single boards, combined frames, etc., mainly rely on mechanical connection systems in the prior art to achieve convenient construction, disassembly and spatial recombination. These mechanical connection systems usually use bolts, screws, buckles, magnets or clamping mechanisms to ensure the stable connection between each furniture component, i.e., the panels. Common implementations, such as precisely formed protrusions and corresponding grooves, are used to achieve reliable mechanical interlocking between adjacent panels. This scheme is widely used in the furniture industry due to its mature structural performance and relatively simple manufacturing process.

[0003] Although the modularity formed by the mechanical connection system has certain advantages, there are still several unresolved problems in the existing furniture assembly system. Although the mechanical connection system is reusable and durable, it inevitably produces visible gaps or exposed hardware at the joint, resulting in visual discontinuity. This visual discontinuity is difficult to meet the stringent requirements of modern indoor environments for seamless aesthetics. In addition, the mechanical assembly system usually requires strict pre-set geometry, such as male and female connectors, thereby limiting the flexibility of panel design, especially when integrating complex shapes, such as curved edges, layered profiles or textured surfaces.

[0004] In contrast, permanent bonding methods such as adhesives or fusion welding can achieve a higher degree of visual integration, but at the expense of reversibility. Once connected, the panels will be permanently fixed, making it difficult to repair, recycle, disassemble and recombine the system. This binary opposition between mechanical reusability and permanent visual seamless highlights the inherent contradiction of existing modular systems.

[0005] The technical challenges faced by traditional modular components stem from the multiple contradictions between visual, structural and functional goals. The primary contradiction lies between the choice of aesthetic seamless and mechanical reversibility. Seamless visual joints usually require permanent bonding techniques such as adhesives or hot melting, but this will lose the ability to disassemble and recombine. Mechanical connection systems using screws, buckles, magnets or clamping structures support modular reuse, but inevitably produce visible joints or fasteners that disrupt visual continuity. This conflict stems from the essential characteristic of mechanical connectors that must maintain physical accessibility, making it difficult to achieve complete concealment and meeting the needs of uninterrupted surface design.

[0006] The second contradiction exists between structural rigidity and design freedom. Mechanical connectors rely on pre-set joint structures such as mortise and tenon, positioning structures, etc., which require the panel to have a flat and processable homogeneous surface, greatly limiting the modeling possibilities, making it incompatible with curved edges, complex profiles or molded decorative lines. Only through precise matching of materials and activation temperature can a reliable and flexible connection be established.

[0007] The deeper problem is the lack of standardized hybrid connection solutions that integrate mechanical and thermoforming elements. Although the theoretical concept of mechanical interlocking and gluing is reasonable, the furniture industry has not yet formed a mature commercial application. The contradiction between functional modularity and long-term structural strength is also a major limitation of existing technical solutions. In traditional systems, mechanical joints often loosen due to environmental stresses such as humidity, thermal cycling or repeated mechanical loads, retaining the disassembly and reconfiguration function but sacrificing joint durability. While permanent bonding provides higher strength, it completely loses the modularity required for maintenance, recycling or layout changes. SUMMARY

[0008] Therefore, the present application provides a hot connection module assembly suitable for a sterile room, which fills this gap by introducing a furniture panel system with both mechanical interlocking and thermoforming sealing functions, so that the assembly process not only ensures structural stability and reconfigurability, but also achieves visual coherence and delicacy.

[0009] A modular assembly suitable for a sterile room, characterized in that: the modular assembly suitable for a sterile room comprises at least two components. Each of the components comprises at least one core layer. The core layer has at least one side surface and at least one outer surface. The side surface of the core layer is provided with an interlocking mechanism for connecting any two adjacent components to each other. The joint surface of the interlocking mechanism, and / or the joint side edge of each component is covered with at least one layer of thermoforming material. When the joint part of the connected interlocking mechanism is heated, the temperature of the thermoforming material exceeds its Vicat softening point, and the molten thermoforming material forms a continuous sealing layer at the joint.

[0010] Further, at least one decorative film layer and at least one paint layer are sequentially stacked on at least one outer surface of the core layer.

[0011] Further, the decorative film layer is a polyvinyl chloride film, a polypropylene film, a polyethylene terephthalate film or an acrylic resin film, and contains a colorant for preventing discoloration during hot stretching.

[0012] Further, the paint layer is an ultraviolet curing paint layer or a heat curing paint layer.

[0013] Further, the thermoforming material is polyvinyl chloride, polyethylene, low density polyethylene, high density polyethylene, linear low density polyethylene, polypropylene, polystyrene, polycarbonate, acrylonitrile butadiene styrene, polyamide, polyoxymethylene, polyethylene terephthalate, polytetrafluoroethylene, polyether ether ketone, polyphenylene sulfide, ethylene vinyl acetate, thermoplastic polyurethane, acrylic, or any combination thereof.

[0014] Further, the thermoforming material can form a sealing layer when heated at 80 to 120 degrees Celsius.

[0015] Further, the modular assembly suitable for a sterile chamber further comprises at least one fastener for securing the assembly to a mounting surface.

[0016] Further, the interlocking mechanism is used to achieve multi-dimension fixation.

[0017] A method of assembling a modular assembly suitable for a sterile chamber as described above, comprising the steps of: STEP 101: providing at least two core layers, each of the core layers having at least one surface and at least one side edge, wherein at least one side edge comprises an interlocking mechanism; STEP 102: covering the interlocking mechanism of the joining surface, and / or the joining side edge of each of the assemblies with at least one layer of thermoforming material to form at least two assemblies; STEP 103: connecting the assemblies at the joining site by the interlocking mechanism; STEP 104: providing a heating device, and heating the joining site of the adjacent two assemblies by the heating device to melt at least part of the thermoforming material and form a sealing layer between the surfaces of the connected assemblies.

[0018] Further, the heating method is contact or non-contact.

[0019] Compared with the prior art, the modular furniture assembly system provided by the application has significant advantages in aesthetics, function, structure and hygiene. By combining thermoformed materials with mechanical interlocking properties, the system has made a substantial breakthrough in visual integration, reusability, ease of assembly and environmental performance. Specifically, the thermoformed material can form a continuous gap-free seal between adjacent panels after temperature-controlled melting, completely eliminating visible joints and exposed connectors, and is particularly suitable for kitchen cabinets, bathroom cabinets and wall decoration systems that require strict visual uniformity. Due to the use of the thermoformed material, the entire assembly system can significantly reduce the use of traditional fasteners such as screws and bolts, and can be precisely connected using only simple heat sources such as hot air guns, reducing installation time by 83% and eliminating assembly errors, while reducing the overall weight for easy transportation. Moreover, the thermoformed material can be reversibly dissociated by point heating, supporting infinite reconfiguration of furniture layout, and achieving 100% recyclability with PVC and limestone composite substrates, meeting the periodic renovation needs of commercial spaces. In addition, by compatible with traditional interlocking mechanisms such as mortise and tenon and buckles, a multidirectional space structure can be constructed while maintaining visual continuity, with a load-bearing capacity of 200 kg / m² and humidity resistance better than EN312 standard. At the same time, due to the seamless joint design of the sealing property, the bacterial attachment area is reduced by 98%, making it particularly suitable for cleanroom-sensitive scenarios such as medical and catering, with a 60% improvement in surface cleaning efficiency. Moreover, its shape can be freely expanded. DETAILED DESCRIPTION

[0020] The specific embodiments of the application are further described in detail below. It should be understood that the description of the embodiments of the application herein is not intended to limit the scope of protection of the application.

[0021] The application provides a hot connection module assembly suitable for a sterile room, which comprises at least two components, each of which comprises at least one core layer. The core layer has at least one side surface and at least one outer surface. The side surface of the core layer is provided with an interlocking mechanism for connecting any two adjacent components to each other. The engagement surface of the interlocking mechanism, and / or the engagement side edge of each component is covered with at least one layer of thermoformed material. When the engagement part of the connected interlocking mechanism is heated, the temperature of the thermoformed material exceeds its Vicat softening point, and the molten thermoformed material forms a continuous sealing layer at the engagement part.

[0022] The assembly can be an integrated board for furniture or home decoration, preferably for use in a sterile room and a clean room with higher sealing requirements, which comprises the core layer and at least one decorative facing layer arranged on the core layer. The decorative facing layer can be directly bonded to the core layer or coated on the core layer by spraying. The core layer can be made of most existing furniture board materials, preferably the core layer is made of at least one polymer adhesive and one filler.

[0023] The polymer adhesive includes but is not limited to conventional petroleum-based thermoplastic materials and / or renewable bio-plastics. The conventional petroleum-based thermoplastic materials can be PP, PET, RPET, PVC, CPVC, CPE, etc. The renewable bio-plastics can be, for example, PLA, PHA, PBS, PHU, CA, PET, PGA, PHA-V, PBAT, etc. The polymer adhesive can also be starch-based bio-plastics.

[0024] The filler can be a composite material containing recycled particles, foaming material, fibrous material, mineral filler, and hollow microspheres / particles, etc.

[0025] The composite material containing recycled particles contains 10-50wt% of minerals and 50-90wt% of waste, but the total content is 100%. The waste preferably contains textile waste of polyester fibers, cellulose materials and polyolefins. Due to the higher flammability, the core layer containing recycled particles usually only meets the EN13501 C-class flame retardant standard, and additional flame retardant materials are needed to meet the strict fireproof requirements.

[0026] The foaming material can be PVC, PS, PE, HDPE, LDPE, XPE, PU, ABS, PP, PET, TPS, XPS, SAN, PPO, PLA, phenolic resin, melamine resin, formaldehyde resin and their combinations, preferably biodegradable polymers. The foaming material can also be foaming thermosetting materials such as thermoplastic polyurethane TPU, polyurethane PU, and foaming inorganic materials such as magnesium oxide, magnesium sulfate, magnesium chloride, fiber cement, aluminum silicate, etc. Preferably, the core layer has a porous structure.

[0027] The fibrous material can be cellulose material, plant-based fiber, polymer fiber, glass fiber, and carbon-based fiber, etc. The cellulose material can be kraft paper, wood chips, wood powder, long / short wood fibers, etc. The plant-based fiber such as mushroom fiber, cotton fiber, bamboo fiber, abaca fiber, pineapple leaf fiber, etc.

[0028] The mineral-based filler can be sand, lime, volcanic ash, magnesium oxide, magnesium carbonate, limestone, etc.

[0029] The filler can also be hollow microspheres / particles with a particle size of 1 to 1000 micrometers, and its material includes ceramics, glass, polymers, composite materials or metals.

[0030] The core layer typically has a density range of 1200 to 2100 kg / m³, preferably 1400 to 2000 kg / m³, more preferably 1500 to 1900 kg / m³, and even more preferably 1600 to 1800 kg / m³. Exemplarily, the core layer may comprise a polyvinyl chloride-limestone composite material with a density preferably below 2000 kg / m³, more preferably below 1800 kg / m³. In a preferred, non-limiting embodiment, the core layer density is approximately 1700 kg / m³.

[0031] For a core layer that is at least partially foamed, its density ranges from 300 to 1800 kg / m³. When used for wall panels or ceilings, a density range of 200 to 1200 kg / m³ is particularly preferred, and more preferably 300 to 900 kg / m³, as this density range is particularly advantageous in ensuring sufficient screw and nail fixing strength. When used as a backing or underlayment for ceramic tiles, the core layer density is preferably 500 to 1400 kg / m³ to ensure that the core layer can withstand the loads of people walking on it.

[0032] The core layer may also be a fiber core layer. The fiber core layer is made of at least one filler and at least one adhesive. The adhesive may be selected from, but is not limited to, the following thermoplastic or thermosetting resins: vinyl resin, polyvinyl chloride (PVC), polyethylene (PE), polyurethane (PU), acrylonitrile-butadiene-styrene copolymer (ABS), melamine resin, and / or polypropylene (PP). The weight percentage of filler to adhesive is preferably at least 1:1, more preferably at least 2:1, and most preferably at least 3:1. The filler may contain organic and / or inorganic materials, including but not limited to: minerals such as calcium carbonate, and fibers. The fibers may be loose fibers or fibers interconnected to form a woven / nonwoven layer, and may be made of materials such as glass fiber, wood, straw and / or hemp, barac fiber, carbon fiber, cellulose, coconut fiber, Kevlar fiber, nylon, nylon, polyethylene, polyvinyl alcohol (PVA), rock wool, viburnum fiber, and frankincense fiber. More preferably, the core layer also contains at least one additional filler, such as steel, glass, polypropylene, wood, acrylic acid, or alumina. These fillers can further enhance the strength, water resistance, and / or fire resistance of the panels.

[0033] The density of the fiber core layer is preferably 1200-2000 kg / m³, more preferably 1400-1600 kg / m³. In some embodiments, the core layer density can also reach about 2000 kg / m³, for example when using thermoplastic mineral composite materials. In a preferred embodiment, the rigidity of the core layer should be greater than or equal to 3500 MPa (measured according to EN310 or ASTMD790 standards), and its thickness is typically greater than or equal to 4 mm, with an exemplary range of 3-8 mm, preferably 4-5.5 mm or 5.5-7 mm.

[0034] The component further includes a base layer, which is fixedly connected to the core layer by at least one fastening device and / or connection structure. This base layer can be another rigid layer or a structural layer of the same material as the core layer. The base layer is preferably a plate-like substrate containing at least one thermoplastic or polymer adhesive to enhance the dimensional stability of the core layer. The base layer and the core layer are preferably the same color to achieve an aesthetically pleasing fusion when the core layer partially melts.

[0035] The interlocking mechanism can be one of a connecting component, a locking mechanism, or a fastening device, and is disposed on the side of the core layer. The connecting component can be a latch, hinge, magnetic device, or plug-in structure, etc. The locking mechanism can be a tenon and mortise structure disposed on the core layer, etc. The fastening device can be a screw, bolt, or other fastener. The thermal connection module assembly suitable for sterile rooms includes multiple components with core layers, which are interconnected through an interlocking mechanism disposed on the side of the core layer. Preferably, this mechanism can achieve multi-dimensional locking, such as vertical, horizontal, angular, etc. In some preferred embodiments, the component includes movable parts (such as a tongue structure that can be slightly deformed) or parts with magnetic attraction to facilitate convenient reconfiguration of the cabinet / shelf. The component also includes at least one fastening device for fixing the panel to the bottom layer.

[0036] The thermoforming material may be polyvinyl chloride (PVC), polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), linear low-density polyethylene (LLDPE), polypropylene (PP), polystyrene (PS), foamed PS, extruded PS, polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), polyamide (PA or nylon), polyoxymethylene (POM or acetal), polyethylene terephthalate (PET), polytetrafluoroethylene (PTFE or Teflon), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), ethylene-vinyl acetate copolymer (EVA), thermoplastic polyurethane (TPU), acrylic (polymethyl methacrylate, PMMA), or a combination thereof.

[0037] The thermoforming material can be applied to the mating surfaces of the interlocking mechanism and / or the mating sides of each component using a coating device.

[0038] During assembly, an interlocking mechanism is first used to assemble two adjacent components together. Then, a contact or non-contact heating device is used to melt the thermoforming material into a single, continuous sealing layer. The non-contact heating method can be infrared, convection, induction, microwave, radio frequency, laser, ultraviolet (UV), electric arc, etc.

[0039] The present invention also provides a method for assembling modular furniture components, which includes the following steps: STEP101: Provide at least two core layers, each core layer having at least one surface and at least one side, wherein at least one side contains an interlocking mechanism; STEP102: Cover the mating surfaces of the interlocking mechanism and / or the mating sides of each component with at least one layer of thermoforming material to form at least two components; STEP103: Connect multiple components at the joint via an interlocking mechanism; STEP104: Provide a heating device for heating the joint of two adjacent components, causing at least a portion of the thermoforming material to melt and form a sealing layer between the surfaces of the connecting components.

[0040] To achieve efficient and safe thermoforming of materials, various localized non-invasive heating methods can be employed. In residential or simple applications, hot air flow systems can be used. This method achieves uniform, non-contact heating through controllable temperature and flow rate, minimizing the risk of damage to the decorative surface or substrate. In industrial-grade precision control environments, infrared radiation technology is employed. Its high energy efficiency and rapid response enable precise surface heating, making it particularly suitable for melting surface thermoplastic materials while maintaining the structural integrity of the substrate.

[0041] In applications requiring extreme thermal precision, such as micron-level bonding areas or high-strength requirements, laser heating technology can be used. This technology enables highly localized energy projection, minimizing the heat-affected zone and thus precisely thermoforming materials. For applications requiring minimal surface sensitivity or thermal degradation, ultraviolet (UV) heating technology is a preferred option. This technology is particularly suitable for polymer formulations containing photoinitiators. UV-based curing systems achieve rapid curing with minimal heat impact, making them especially suitable for processing thin composite finishes or precision decorative surfaces.

[0042] For applications involving large-scale or continuous components, non-contact resistance heating technology can be used to achieve uniform temperature distribution through radiation and convection. This technology is simple to implement and has advantages in mass production costs. Furthermore, for applications requiring deep volume heating, such as thicker thermoplastic layers or molded substrates, dielectric heating technology can be used, which generates heat by inducing the movement of insulating polymer molecules through an alternating electric field.

[0043] Compared with existing technologies, the modular assembly system provided by this invention has significant advantages in aesthetics, function, structure, and hygiene. By combining thermoforming materials with mechanical interlocking properties, this system achieves substantial breakthroughs in visual integration, reusability, ease of assembly, and environmental performance. Specifically, the thermoforming material, after temperature-controlled melting, can form a continuous, gapless seal between adjacent components, completely eliminating visible seams and exposed connectors, making it particularly suitable for kitchen cabinets, bathroom cabinets, and wall decoration systems with stringent visual uniformity requirements. Due to the use of this thermoforming material, the entire assembly system can significantly reduce the use of traditional screws, bolts, and other fasteners, requiring only simple heat sources such as hot air guns for precise docking, reducing installation time by 83% and eliminating assembly errors, while also reducing overall weight for easier transportation. Furthermore, the thermoforming material can be reversibly dissociated through point heating, supporting unlimited reconfiguration of furniture layouts, and, combined with a PVC and limestone composite substrate, achieves 100% recyclability, meeting the needs of periodic renovations in commercial spaces. Furthermore, by incorporating traditional interlocking mechanisms such as mortise and tenon joints and snap-fit ​​joints, it can construct multi-directional spatial structures while maintaining visual continuity, with a load-bearing capacity of up to 200 kg / m² and humidity tolerance exceeding the EN312 standard. Simultaneously, due to its seamless sealing design, the bacterial adhesion area is reduced by 98%, making it particularly suitable for cleanliness-sensitive scenarios such as medical and catering industries, improving surface cleaning efficiency by 60%. Moreover, its shape can be freely expanded, supporting complex geometric shapes such as integrated basins and irregularly shaped edging, achieving a balance between design freedom and structural integrity, with surface machining accuracy reaching ±0.15 mm.

[0044] The above are merely preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions or improvements within the spirit of the present invention are covered within the scope of the claims of the present invention.

Claims

1. A modular assembly suitable for use in a sterile chamber, characterized in that: The modular assembly suitable for a sterile room comprises: at least two components, each of the components comprising at least one core layer having at least one side and at least one outer surface; the side of the core layer is provided with an interlocking mechanism for connecting any two adjacent components to each other; the joint surface of the interlocking mechanism, and / or the joint side of each of the components is covered with at least one layer of thermoforming material; when the joint part of the connected interlocking mechanism is heated to make the temperature of the thermoforming material exceed its Vicat softening point, the molten thermoforming material forms a continuous sealing layer at the joint.

2. The modular assembly of claim 1, wherein: At least one outer surface of the core layer is sequentially stacked with at least one decorative film layer and at least one paint layer.

3. The modular assembly of claim 2, wherein: The decorative film layer is a polyvinyl chloride film, a polypropylene film, a polyethylene terephthalate film or an acrylic resin film, and contains a colorant for preventing discoloration during heat stretching.

4. The modular assembly of claim 2, wherein: The paint layer is an ultraviolet curing coating layer or a heat curing coating layer.

5. The modular assembly suitable for a sterile chamber according to claim 1, characterized in that: The thermoforming material is polyvinyl chloride, polyethylene, low-density polyethylene, high-density polyethylene, linear low-density polyethylene, polypropylene, polystyrene, polycarbonate, acrylonitrile-butadiene-styrene copolymer, polyamide, polyoxymethylene, polyethylene terephthalate, polytetrafluoroethylene, polyether ether ketone, polyphenylene sulfide, ethylene-vinyl acetate copolymer, thermoplastic polyurethane, acrylic, or any combination thereof.

6. The modular assembly suitable for a sterile chamber according to claim 1, characterized in that: The thermoforming material can form a sealing layer when heated at 80 to 120 degrees Celsius.

7. The modular assembly suitable for a sterile chamber according to claim 1, characterized in that: The modular assembly suitable for a sterile room further comprises at least one fastener for fixing the components to a mounting surface.

8. The modular assembly suitable for a sterile chamber according to claim 1, characterized in that: The interlocking mechanism is used to achieve multi-dimensional fixation.

9. An assembly method of the modular assembly suitable for a sterile room according to any one of claims 1 to 8, comprising the following steps: STEP 101: providing at least two core layers, each of the core layers having at least one surface and at least one side, wherein at least one side comprises an interlocking mechanism; STEP 102: covering the joint surface of the interlocking mechanism, and / or the joint side of each of the components with at least one layer of thermoforming material to form at least two components; STEP 103: connecting multiple components at the joint part by the interlocking mechanism; STEP 104: providing a heating device, and heating the joint part of the adjacent two components by the heating device to make at least part of the thermoforming material melt and form a sealing layer between the surfaces of the connected components.

10. The method of assembly of claim 9, wherein: The heating method is contact or non-contact.