Door leaf and manufacturing method thereof

Abstract

The invention discloses a door leaf and a manufacturing method thereof, and relates to the technical field of door leafs.The method comprises the steps that PU foaming glue is evenly injected into a visual containing space formed by one door skin and a framework, and the other door skin is placed on the door skin and the framework where the PU foaming glue is injected and sent into a pressing machine to be pressed; and after the PU foaming glue is foamed and cured, the press is removed, and the door leaf is obtained. Glue is injected into the visible containing space which is formed by the framework and the door skin and provided with the top opening in a plane mode, so that PU foaming glue is evenly injected in a visible state before being fed into a pressing machine, sufficient reaction and even distribution of the glue are guaranteed, the flatness of a door leaf is guaranteed, PU foaming materials are saved, and the yield is increased.

Description

Technical Field

[0001] This invention relates to the field of door panel technology, specifically to a door panel and its manufacturing method. Background Technology

[0002] In existing technologies, both domestically and internationally, the production of door panels filled with PU foam (Polyurethane foam sealing agent) involves first constructing a sealed door panel cavity using a door skin and frame, placing it in a press, and then injecting PU foam through the injection hole on the door panel. In this process, the rapidly injected PU foam tends to accumulate on the inner side of the door panel cavity, away from the injection hole. The PU foam undergoes a rapid chemical reaction within the cavity, gradually moving towards the injection hole and filling the door panel cavity. However, the reaction process generates a large amount of gas. If this gas is not released in time, the accumulated gas will create waves on the door surface. This is especially problematic for thin door panels (such as metal doors), as the surface waves easily lead to product defects and significant scrap. The low yield rate of PU foam door panels is an international technical challenge plaguing the industry. When manufacturing glass doors, existing technologies also require filling the PU foam and constructing the door panel before using tools such as a jigsaw to cut glass holes. This generates a large amount of solid waste and wastes a significant amount of PU foam material. Summary of the Invention

[0003] This invention provides a door leaf and a method for manufacturing the same, which solves the above-mentioned problems.

[0004] This invention provides a method for manufacturing a door leaf, comprising: Step 1: Evenly inject PU foam adhesive into the visible space consisting of a door skin and a frame. Place another door skin on the door skin and frame that have been injected with PU foam adhesive and send it into the press to press together. Step 2: After the PU foam adhesive has foamed and cured, remove the press to obtain the door panel.

[0005] Optionally, step 1 specifically involves: within a first preset time period, uniformly injecting PU foam adhesive into the visible space consisting of a door skin and a frame, placing another door skin on the door skin and frame that have been injected with PU foam adhesive, and sending it into a press for pressing.

[0006] Optionally, both door panels have openings; the positions of the openings correspond to the positions of the inner molds of the glass holes. Step 1 is as follows: evenly inject PU foam adhesive into the visible space consisting of a door skin, frame and glass hole inner mold, place another door skin on the door skin, frame and glass hole inner mold that have been injected with PU foam adhesive and send it into the press to press together.

[0007] Optionally, the inner mold of the glass hole is placed around the opening, and a sealing ring is fitted over the outer layer of the inner mold of the glass hole.

[0008] Optionally, after step 2, the process also includes: removing the inner mold of the glass hole and installing glass at the opening.

[0009] Optionally, step 1 specifically involves: within a first preset time period, uniformly injecting PU foam adhesive into the visible receiving space consisting of a door skin, a frame, and a glass hole inner mold; placing another door skin on the door skin, frame, and glass hole inner mold that have been injected with PU foam adhesive and sending it into a press for pressing.

[0010] Optionally, step 2 specifically involves: after the PU foam adhesive has foamed and cured for a second preset time, removing the press to obtain the door panel.

[0011] Optionally, the inner mold of the glass hole includes: two sets of telescopic opening and closing mechanisms; each set of opening and closing mechanisms includes: a base, a movable arm, and a connecting rod structure; one end of the movable arm is hinged to the base; the connecting rod mechanism includes: two oblique connecting rods respectively connecting the movable arm and the bottom of the base, the connecting rod structure, the base, and the movable arm forming a triangular structure, and the movable arm is rotated by the movement of the connecting rod to realize the opening and closing function of the inner mold of the glass hole.

[0012] A door leaf manufactured according to a door leaf manufacturing method, wherein the door leaf skin and frame are filled with PU foam adhesive.

[0013] The beneficial effects of the present invention are as follows: The door leaf and its manufacturing method provided by the present invention inject PU foam adhesive into a visible receiving space with a top opening in the frame and door skin, so that the PU foam adhesive is injected evenly in a visible state before being pressed, ensuring that the adhesive reacts fully and is evenly distributed, thereby ensuring the flatness of the door leaf, saving PU foam material, and improving the yield. Attached Figure Description

[0014] Figure 1 This is a plan view of a visible accommodating space c1 with a top opening, formed by the skeleton b and the door skin a1 provided in Embodiment 2 of the present invention.

[0015] Figure 2 This is a cross-sectional schematic diagram of a visible accommodating space c1 with a top opening, formed by the skeleton b and the door skin a1 provided in Embodiment 2 of the present invention.

[0016] Figure 3 This is a schematic diagram of the visible receiving space c1 formed by the skeleton b and the door skin a1 provided in Embodiment 2 of the present invention.

[0017] Figure 4 This is a plan view of the door skin e1 provided in Embodiment 2 of the present invention.

[0018] Figure 5 This is a plan view of a visible accommodating space c2 with a top opening, formed by the skeleton b, door skin a2, and glass hole inner mold f provided in Embodiment 3 of the present invention.

[0019] Figure 6 This is a cross-sectional schematic diagram of a visible accommodating space c2 with a top opening, formed by the skeleton b, the door skin a2, and the inner glass mold f provided in Embodiment 3 of the present invention.

[0020] Figure 7 This is a schematic diagram of the visible receiving space c2 with a top opening, formed by injecting PU foam adhesive d into the skeleton b, door skin a2, and glass hole inner mold f, as provided in Embodiment 3 of the present invention.

[0021] Figure 8 This is a plan view of the door skin e2 provided in Embodiment 3 of the present invention.

[0022] Figure 9 This is a schematic diagram of the retractable opening and closing mechanism f1 of the glass hole inner mold f provided in Embodiment 3 of the present invention. Detailed Implementation

[0023] The technical solutions of this invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. Example 1

[0024] This embodiment provides a method for manufacturing a door leaf, including: Step 1: Evenly inject PU foam adhesive into the visible space consisting of a door skin and a frame. Place another door skin on the door skin and frame that have been injected with PU foam adhesive and send it into the press to press together. Step 2: After the PU foam adhesive has foamed and cured, remove the press to obtain the door panel.

[0025] Preferably, step 1 specifically involves: within a first preset time period, uniformly injecting PU foam adhesive into the visible space consisting of a door skin and a frame, placing another door skin on the door skin and frame that have been injected with PU foam adhesive, and sending it into a press for pressing.

[0026] Preferably, both door panels have openings; the positions of the openings correspond to the positions of the inner molds of the glass holes. Step 1 is as follows: evenly inject PU foam adhesive into the visible space consisting of a door skin, frame and glass hole inner mold, place another door skin on the door skin, frame and glass hole inner mold that have been injected with PU foam adhesive and send it into the press to press together.

[0027] Preferably, the inner mold of the glass hole is placed around the opening, and a sealing ring is fitted over the outer layer of the inner mold of the glass hole.

[0028] Preferably, after step 2, the method further includes: removing the inner mold of the glass hole and installing glass at the opening.

[0029] Preferably, step 1 specifically involves: within a first preset time period, uniformly injecting PU foam adhesive into the visible accommodating space consisting of a door skin, a frame, and a glass hole inner mold; placing another door skin on the door skin, frame, and glass hole inner mold that have been injected with PU foam adhesive and sending it into a press for pressing.

[0030] Preferably, step 2 specifically involves: after the PU foam adhesive has foamed and cured for a second preset time, the press is removed to obtain the door panel.

[0031] Preferably, the inner mold of the glass hole includes: two sets of telescopic opening and closing mechanisms; each set of opening and closing mechanisms includes: a base, a movable arm, and a connecting rod structure; one end of the movable arm is hinged to the base; the connecting rod mechanism includes: two oblique connecting rods that connect the movable arm and the bottom of the base respectively, and the connecting rod structure, the base, and the movable arm form a triangular structure, and the movable arm is rotated by the movement of the connecting rod to realize the opening and closing function of the inner mold of the glass hole.

[0032] This embodiment also provides a door leaf manufactured according to a door leaf manufacturing method, wherein the door leaf skin and frame are filled with PU foam adhesive.

[0033] This embodiment provides a door leaf and its manufacturing method. By injecting adhesive into a visible space with a top opening within the frame and door skin, the PU foam adhesive is injected evenly under visible conditions before being pressed, ensuring that the adhesive reacts fully and is evenly distributed, thereby ensuring the flatness of the door leaf, saving PU foam material, and improving the yield. Example 2

[0034] This embodiment provides a method for manufacturing a door leaf, including: The first step is to place the frame b on the door skin a1 to form a visible storage space c1 with a top opening.

[0035] The visible storage space c1, formed by the frame b and the door skin a1, has a top opening. Figures 1-2 As shown.

[0036] Furthermore, within the first preset time period: Under visible conditions, first, the PU foam adhesive d is evenly injected into the visible receiving space c1 formed by the frame b and the door skin a1; then, the door skin e1 is placed over the receiving space c1 formed by the frame b and the door skin a1, which has been injected with PU foam adhesive d; then, the combined door skin e1, PU foam adhesive d, frame b, and door skin a1 are fed into the press via a high-speed conveyor belt for rapid pressing and waiting for foaming.

[0037] PU foam adhesive d is injected into the visible space c1 formed by the skeleton b and the door skin a1. Figure 3 As shown, door skin e1 is as follows Figure 4 As shown.

[0038] In this embodiment, the pre-foaming time of the PU foam adhesive is within a first preset time. The pre-foaming time of the PU foam adhesive refers to the time interval from when the PU foam adhesive is injected into the receiving space to when foaming begins.

[0039] For example, the first preset time can be 40 seconds.

[0040] Furthermore, after the PU foam adhesive has cured, the press can be removed to produce the door leaf.

[0041] Preferably, after the PU foam adhesive has cured for 15 minutes, the press can be removed to produce the door leaf.

[0042] It should be noted that after the two layers of door skin are pressed together, a gap is usually left to allow gas generated during the reaction of the PU foam adhesive to escape. Alternatively, a gas channel (such as an opening) can be created in the door leaf for venting. The door leaf and its manufacturing method provided in this embodiment inject adhesive into a visible, open-top space within the frame and door skin. This ensures that the PU foam adhesive is injected evenly and visiblely before being pressed, guaranteeing a full reaction and uniform distribution of the adhesive. This significantly reduces the uneven distribution of the PU foam adhesive within the door leaf caused by rapid movement during the injection process through the injection hole after pressing, as well as the phenomenon of uneven surface ripples caused by localized large amounts of gas, which occurs in existing technologies. This ensures the flatness of the door leaf and improves the yield rate. Example 3

[0043] This embodiment provides a door leaf and its manufacturing method, including: The first step is to make holes in door skin a2 and door skin e2; Furthermore, place the frame b on the door skin a2.

[0044] Furthermore, the inner mold f of the glass hole is placed at the position of the opening corresponding to the door skin a2, forming a visible receiving space c2 with a top opening, the specific structure of which is as follows: Figure 5-6 As shown.

[0045] Specifically, the inner mold f of the glass hole is placed around the opening, and the outer layer of the inner mold of the glass hole is fitted with a sealing ring to prevent PU foam adhesive from overflowing into the opening.

[0046] Furthermore, within the first preset time period: Under visible conditions, PU foam adhesive d is evenly injected into the visible receiving space c2, which is formed by the door skin a2, the frame b, and the inner mold of the glass hole f, and has a top opening. Figure 7 As shown; then, as Figure 8 The door skin e2 shown covers the door skin a1, which has been injected with PU foam adhesive d, and together with the skeleton b and the inner mold of the glass hole f, it forms a visible receiving space c2; then the assembled door skin e2, PU foam adhesive d, skeleton b, inner mold of the glass hole f, and door skin a2 are put into the press through a high-speed conveyor belt for rapid pressing and waiting for foaming.

[0047] In this embodiment, the pre-foaming time of the PU foam adhesive is within a first preset time. The pre-foaming time of the PU foam adhesive refers to the time interval from when the PU foam adhesive is injected into the receiving space to when foaming begins.

[0048] For example, the first preset time can be 40 seconds.

[0049] Furthermore, after the PU foam adhesive has cured, the press is removed, the inner mold f of the glass hole is taken out, and the door leaf can be made.

[0050] Preferably, after the PU foam adhesive has cured for 15 minutes, the press is removed, the inner mold f of the glass hole is taken out, and the door leaf can be made.

[0051] like Figure 9 As shown, the inner mold f of the glass hole includes: two sets of telescopic opening and closing mechanisms f1; symmetrically placed around the opening; each opening and closing mechanism includes: a base f1-1, a movable arm f1-2, and a connecting rod structure f1-3; one end of the movable arm f1-2 is hinged to the base f1-1; the connecting rod mechanism f1-3 includes: two oblique connecting rods respectively connecting the movable arm f1-2 and the bottom of the base f1-1, the connecting rod structure f1-3, the base f1-1, and the movable arm f1-2 form a triangular structure, and the movable arm f1-2 is rotated by the movement of the connecting rods to realize the opening and closing function of the inner mold f of the glass hole. Specifically, pushing the connecting rod mechanism f1-3 inward causes the movable arm f1-2 to move inward, thus removing the inner mold f of the glass hole; Push the linkage mechanism f1-3 outward, and the movable arm f1-2 moves outward to support the sealing ring and prevent PU foam adhesive from overflowing into the opening.

[0052] It should be noted that after the two layers of door skin are pressed together, a gap is usually left to allow gas generated during the reaction of the PU foam adhesive to escape. Alternatively, a gas channel (such as an opening) can be created in the door leaf for venting. The door leaf and its manufacturing method provided in this embodiment inject adhesive into a visible, open-top space within the frame, door skin, and glass hole mold. This allows the PU foam adhesive to be injected evenly and visiblely before being pressed, ensuring sufficient reaction and uniform distribution of the adhesive. This significantly reduces the uneven distribution of the PU foam adhesive within the door leaf caused by rapid movement during injection through the injection hole after pressing, as well as the phenomenon of uneven surface ripples caused by localized gas generation during the injection process in existing technologies. This ensures the flatness of the door leaf and improves the yield rate. Furthermore, this embodiment creates the opening before filling the PU foam adhesive, which, compared to existing technologies where the glass hole is made after the door leaf is finished and then cut using tools such as a jigsaw, saves on PU foam adhesive filling material at the glass hole location.

[0053] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for manufacturing a door leaf, characterized in that, include: Step 1: Evenly inject PU foam adhesive into the visible space consisting of a door skin and a frame. Place another door skin on the door skin and frame that have been injected with PU foam adhesive and send it into the press to press together. Step 2: After the PU foam adhesive has foamed and cured, remove the press to obtain the door panel.

2. The method for manufacturing a door leaf according to claim 1, characterized in that, Step 1 specifically involves: within a first preset time period, uniformly injecting PU foam adhesive into the visible space consisting of a door skin and a frame, placing another door skin on the door skin and frame that have been injected with PU foam adhesive, and then sending it into a press for pressing.

3. The method for manufacturing a door leaf according to claim 1, characterized in that, Both door panels have openings; the positions of the openings correspond to the positions of the inner molds in the glass. Step 1 is as follows: evenly inject PU foam adhesive into the visible space consisting of a door skin, frame and glass hole inner mold, place another door skin on the door skin, frame and glass hole inner mold that have been injected with PU foam adhesive and send it into the press for pressing.

4. The method for manufacturing a door leaf according to claim 3, characterized in that, The inner mold of the glass hole is placed around the opening, and a sealing ring is fitted over the outer layer of the inner mold of the glass hole.

5. The method for manufacturing a door leaf according to claim 3, characterized in that, After step 2, the process also includes: removing the inner mold of the glass hole and installing the glass at the opening.

6. The method for manufacturing a door leaf according to claim 3, characterized in that, Step 1 is as follows: within the first preset time period, PU foam adhesive is evenly injected into the visible space consisting of a door skin, frame and glass hole inner mold, and another door skin is placed on the door skin, frame and glass hole inner mold that have been injected with PU foam adhesive and sent into the press for pressing.

7. The method for manufacturing a door leaf according to claim 1, characterized in that, Step 2 specifically involves: after the PU foam adhesive has foamed and cured for a second preset time, the press is removed to obtain the door panel.

8. The method for manufacturing a door leaf according to claim 3, characterized in that, The inner mold of the glass hole includes: two sets of telescopic opening and closing mechanisms; each set of opening and closing mechanisms includes: a base, a movable arm, and a connecting rod structure; one end of the movable arm is hinged to the base; the connecting rod mechanism includes: two oblique connecting rods that connect the movable arm and the bottom of the base respectively, and the connecting rod structure, the base, and the movable arm form a triangular structure. The movable arm is rotated by the movement of the connecting rods to realize the opening and closing function of the inner mold of the glass hole.

9. A door leaf manufactured according to the method of manufacturing a door leaf according to any one of claims 1-8, characterized in that, The door leaf and frame are filled with PU foam adhesive.

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