Joint veneering forming system and production method for flame-retardant composite material of integral cabinet

Abstract

The invention discloses an integral cabinet flame-retardant composite material joint veneering forming system and a production method, and relates to the technical field of flame-retardant composite material production, the integral cabinet flame-retardant composite material joint veneering forming system comprises a mold unit, a membrane positioning and conveying unit, a base material feeding unit, a positive and negative pressure control unit, a heating and temperature control unit and an intelligent control unit, the intelligent control unit is in two-way communication connection with the diaphragm positioning and conveying unit, the base material feeding unit, the positive and negative pressure control unit and the heating and temperature control unit, and the problems that a decorative film layer is prone to displacement and needs to be additionally glued in a traditional process are solved by integrating the intelligent control unit and the positive and negative pressure control unit. The mold unit is vacuumized in the preset stage, so that the membrane is accurately adsorbed; positive pressure is switched in the filling and curing stage, the base material is compacted, and melting or crosslinking of interface molecules is promoted. Therefore, the adhesive-free integrated combination is realized.

Description

Technical Field

[0001] This invention relates to the field of flame-retardant composite material production technology, specifically to a bonding and molding system and production method for flame-retardant composite materials for integrated cabinets. Background Technology

[0002] Flame-retardant composite material for integrated cabinets is a high-performance material designed specifically for furniture, electrical cabinets, energy storage cabinets and other applications. It is made by combining a flame-retardant base material with a functional veneer layer, combining fire safety, structural strength and environmental durability.

[0003] According to the patent titled "A Flame-Retardant Thermal Insulation Composite Board Production Line and its Production Process" (Patent Publication No.: CN115593718A, Patent Publication Date: 2023-01-13), the system includes: a transport device suitable for transporting boards; a cleaning device positioned above the transport device for cleaning the boards being transported; a compaction device positioned above the transport device and on one side of the cleaning device for compacting the cleaned boards; and a handling device positioned above the transport device and on one side of the compaction device for handling the boards after cleaning and applying adhesive. This system achieves the cleaning of the boards and allows for partial application of adhesive to certain areas of the boards, preventing the outer packaging from being too tightly adhered after applying adhesive to the entire board, thus avoiding adhesive waste.

[0004] Based on the aforementioned existing technologies, the current bonding and laminating molding systems and production methods for flame-retardant composite materials for integrated cabinets still have the following problems: In traditional processes, when injecting the substrate, the pre-placed decorative film layer is prone to displacement or wrinkling, leading to product appearance defects or even scrap. Moreover, traditional methods usually rely on applying adhesive to the bonding surface to achieve bonding between the substrate and the film layer, which not only increases the number of processes and costs but also poses risks such as adhesive aging, poor environmental performance, and insufficient bonding strength. Therefore, this invention provides a bonding and laminating molding system and production method for flame-retardant composite materials for integrated cabinets. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a bonding and molding system and production method for flame-retardant composite materials for integrated cabinets. This solves the problems in traditional processes where the pre-placed decorative film layer is prone to shifting or wrinkling during substrate injection, leading to product appearance defects or even scrap. Furthermore, traditional methods typically rely on applying adhesive to the bonding surface to achieve bonding between the substrate and the film layer, which not only increases the number of processes and costs but also poses risks such as adhesive aging, poor environmental performance, and insufficient bonding strength.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution: a bonding and laminating molding system for flame-retardant composite materials of an integrated cabinet, comprising a mold unit, a diaphragm positioning and conveying unit, a substrate feeding unit, a positive and negative pressure control unit, a heating and temperature control unit, and an intelligent control unit. The intelligent control unit is bidirectionally connected to the diaphragm positioning and conveying unit, the substrate feeding unit, the positive and negative pressure control unit, and the heating and temperature control unit. The diaphragm positioning and conveying unit, the substrate feeding unit, the positive and negative pressure control unit, and the heating and temperature control unit are bidirectionally connected to the mold unit. The diaphragm positioning and conveying unit is used to accurately convey and fix the decorative film layer with flame-retardant properties into the cavity of the mold unit, so that the decorative surface of the decorative film layer faces the surface of the mold cavity and the bonding surface faces the inside of the cavity. The positive and negative pressure control unit is connected to the mold unit and is used to selectively establish a negative pressure environment or a positive pressure environment in the cavity at different stages of the molding process, so as to achieve precise adsorption of the decorative film layer and compaction of the substrate respectively.

[0007] Preferably, the positive and negative pressure control unit operates as follows: During the pre-positioning stage of the decorative film layer, the mold cavity is evacuated to ensure that the decorative film layer is tightly adsorbed onto the surface of the mold cavity, preventing the film from shifting when the substrate is injected. During the substrate filling and curing stage, a positive pressure environment is switched to compact the substrate and promote molecular-level melting or cross-linking reactions at the interface between the substrate and the decorative film layer.

[0008] Preferably, a surface activation treatment unit is further included between the diaphragm positioning and conveying unit and the mold unit. The surface activation treatment unit is a low-temperature plasma generator, which is disposed between the diaphragm positioning and conveying unit and the mold unit, and at the output end of the substrate feeding unit. It is used to perform online activation treatment on the bonding surface of the decorative film layer and the surface of the flame-retardant composite material substrate before the substrate is filled, so as to introduce active groups to improve the interfacial bonding strength.

[0009] Preferably, the substrate feeding unit is a multi-layer co-injection or co-pressure feeding device used to provide a flame-retardant composite material with gradient functions, which, after molding, forms a resin-rich dense surface layer near the decorative film layer and a lightweight reinforcing layer inside.

[0010] Preferably, the mold unit integrates a near-infrared spectral sensor, which is connected to the intelligent control unit for online detection of the curing degree of the bonding interface. The intelligent control unit automatically adjusts the process parameters for the next molding cycle based on the detection results.

[0011] Preferably, the mold unit is a resin transfer molding mold or compression molding mold suitable for irregular curved surfaces or deep cavity structures; the decorative film layer conveyed by the diaphragm positioning and conveying unit is a highly ductile oriented stretch film.

[0012] This invention also discloses a method for producing flame-retardant composite materials for integrated cabinets, comprising the following steps: S1: In-mold decoration pretreatment step: The decorative film layer with flame-retardant properties is pre-placed in the cavity of the mold unit through the film positioning and conveying unit, and the cavity is evacuated by the positive and negative pressure control unit so that the decorative film layer is tightly adsorbed on the mold surface. S2: Substrate filling and molding step: Flame-retardant composite material substrate is injected or pressed into the mold cavity with the decorative film layer pre-placed by the substrate feeding unit; S3: In-mold curing bonding step: The mold temperature is precisely controlled by the heating and temperature control unit, and the positive and negative pressure control unit switches to a positive pressure environment, so that the flame-retardant composite material substrate flows, fills and cures in the mold. Temperature and pressure are used to cause the bonding surface between the substrate and the decorative film layer to undergo molecular-level melting or cross-linking reaction, forming an integrated bonding interface without adhesive layer. S4: Demolding step: Open the mold and remove the flame-retardant composite material cabinet component with a permanent decorative protective layer on the surface.

[0013] Preferably, in step S1, the decorative film layer is a multi-layer composite structure, comprising: a scratch-resistant transparent flame-retardant layer on the outer surface, a pattern printing layer in the middle, and a functional hot-melt bonding layer on the inner surface; the melting point of the material of the functional hot-melt bonding layer is lower than the curing temperature of the flame-retardant composite material substrate.

[0014] This invention provides a bonding and molding system and production method for flame-retardant composite materials used in integrated cabinets. Compared with existing technologies, it has the following advantages: 1. The bonding and molding system and production method for the flame-retardant composite material of this integrated cabinet solves the problems of easy displacement of the decorative film layer and the need for additional adhesive application in traditional processes by integrating an intelligent control unit and a positive and negative pressure control unit. During the pre-setting stage, a vacuum is applied to the mold unit to ensure precise film adsorption; during the filling and curing stage, positive pressure is switched to compact the substrate and promote the melting or cross-linking of interface molecules. This achieves an integrated bonding without adhesives.

[0015] 2. The bonding and molding system and production method for the flame-retardant composite material of this integrated cabinet solves the technical problem of insufficient interfacial bonding in irregular or deep cavity structures by introducing a low-temperature plasma generator as a surface activation treatment unit. This device performs online activation treatment on the bonding surface of the decorative film and the substrate surface before substrate filling, introducing active groups, thereby enhancing the bonding force between the flame-retardant composite material substrate and the decorative film at the molecular level, ensuring the durability and structural stability of the final product in complex usage environments. 3. The bonding and laminating molding system and production method for the flame-retardant composite material of this integrated cabinet adopts a mold unit with an integrated near-infrared spectral sensor, solving the problem of not being able to monitor the curing quality in real time during the production process. This sensor detects the degree of curing at the bonding interface online and feeds the data back to the intelligent control unit, which automatically adjusts the temperature, pressure, and other process parameters for the next cycle. This closed-loop control system achieves intelligent and adaptive adjustment of the production process, ensuring a high degree of consistency in product quality between batches and reducing the scrap rate. Attached Figure Description

[0016] Figure 1 This is a system connection block diagram of the present invention; Figure 2 This is a flowchart of the method of the present invention.

[0017] In the diagram: 1. Mold unit; 2. Diaphragm positioning and conveying unit; 3. Substrate feeding unit; 4. Positive and negative pressure control unit; 5. Heating and temperature control unit; 6. Intelligent control unit. Detailed Implementation

[0018] 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. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figures 1-2 The present invention provides a technical solution: A bonding and laminating molding system and production method for flame-retardant composite materials for integrated cabinets includes a mold unit 1, a diaphragm positioning and conveying unit 2, a substrate feeding unit 3, a positive and negative pressure control unit 4, a heating and temperature control unit 5, and an intelligent control unit 6. The intelligent control unit 6 is bidirectionally connected to the diaphragm positioning and conveying unit 2, the substrate feeding unit 3, the positive and negative pressure control unit 4, and the heating and temperature control unit 5. The diaphragm positioning and conveying unit 2, the substrate feeding unit 3, the positive and negative pressure control unit 4, and the heating and temperature control unit 5 are bidirectionally connected to the mold unit 1. The diaphragm positioning and conveying unit 2 is used to accurately convey and fix the decorative film layer with flame-retardant properties into the cavity of the mold unit 1, so that the decorative surface of the decorative film layer faces the surface of the mold cavity and the bonding surface faces the inside of the cavity. The positive and negative pressure control unit 4 is connected to the mold unit 1 and is used to selectively establish a negative pressure environment or a positive pressure environment in the cavity at different stages of the molding process, so as to achieve precise adsorption of the decorative film layer and compaction of the substrate respectively.

[0020] Mold unit 1 has a molding cavity that matches the shape of the cabinet component for accommodating and curing a flame-retardant composite material substrate. Substrate feeding unit 3 is used to mix, meter and feed flame-retardant composite material substrate to the mold unit 1; The heating and temperature control unit 5 is used to precisely control the mold temperature so that it follows a preset heating curve to achieve substrate curing and form an integrated bonding interface between the substrate and the decorative film layer. The intelligent control unit 6 is connected to each of the above units to coordinate and control the entire molding process, so as to achieve one-time in-mold molding without adhesive layer.

[0021] In this embodiment, the positive and negative pressure control unit 4 operates as follows: During the pre-positioning stage of the decorative film layer, the mold cavity is evacuated to ensure that the decorative film layer is tightly adsorbed onto the surface of the mold cavity, preventing the film from shifting when the substrate is injected. During the substrate filling and curing stage, a positive pressure environment is switched to compact the substrate and promote molecular-level melting or cross-linking reactions at the interface between the substrate and the decorative film layer.

[0022] By using the positive and negative pressure control unit 4 to evacuate the mold unit 1 during the pre-setting stage of the decorative film layer, and switching to positive pressure during the substrate filling and curing stage, the problems of easy film displacement and insufficient interface bonding strength in traditional processes are solved, and an integrated and efficient bonding without adhesive is achieved.

[0023] In this embodiment, a surface activation treatment unit is also included between the diaphragm positioning and conveying unit 2 and the mold unit 1. The surface activation treatment unit is a low-temperature plasma generator, which is set between the diaphragm positioning and conveying unit 2 and the mold unit 1, and at the output end of the substrate feeding unit 3. It is used to perform online activation treatment on the bonding surface of the decorative film layer and the surface of the flame-retardant composite material substrate before the substrate is filled, so as to introduce active groups to improve the interfacial bonding strength.

[0024] The surface activation treatment unit employs atmospheric pressure dielectric barrier discharge technology, using compressed air as the working gas. High-energy particles are generated by ionization through a high-voltage electric field, which bombard the material surface to achieve cleaning and activation.

[0025] By setting a low-temperature plasma generator as a surface activation treatment unit between the diaphragm positioning and conveying unit 2 and the mold unit 1 and at the output end of the substrate feeding unit 3, the bonding surface is activated online, which significantly improves the interfacial bonding strength between the flame-retardant composite material substrate and the decorative film layer, and eliminates the risk of bonding failure caused by low surface energy.

[0026] In this embodiment, the substrate feeding unit 3 is a multi-layer co-injection or co-pressure feeding device, used to provide a flame-retardant composite material with gradient function. After molding, the material forms a resin-rich dense surface layer near the decorative film layer and a lightweight reinforcing layer inside.

[0027] By using a multi-layer co-injection or co-pressure feeding device as the substrate feeding unit 3, the gradient functional design of flame-retardant composite materials is realized. After molding, a resin-rich dense surface layer close to the decorative film layer and a lightweight reinforcing layer inside are formed. While ensuring appearance quality and flame-retardant performance, the weight and cost of the overall cabinet are effectively reduced.

[0028] In this embodiment, the mold unit 1 integrates a near-infrared spectral sensor, which is connected to the intelligent control unit 6 for online detection of the curing degree of the bonding interface. The intelligent control unit 6 automatically adjusts the process parameters of the next molding cycle based on the detection results.

[0029] The near-infrared spectral sensor employs diffuse reflectance measurement, using a fiber optic probe to penetrate a sapphire window on the mold to acquire characteristic spectral information of the material at the bonding interface in real time. The degree of curing is then quantitatively calculated using a built-in chemometric model. By integrating the near-infrared spectral sensor into mold unit 1 and connecting it to the intelligent control unit 6, online detection and closed-loop control of the curing degree at the bonding interface are achieved. This solves the problem of large fluctuations in production quality and ensures the performance stability and process consistency of each batch of products.

[0030] In this embodiment, mold unit 1 is a resin transfer molding mold or compression molding mold suitable for irregular curved surfaces or deep cavity structures; the decorative film layer conveyed by diaphragm positioning and conveying unit 2 is a highly ductile oriented stretch film.

[0031] This invention also discloses a method for producing flame-retardant composite materials for integrated cabinets, comprising the following steps: S1: In-mold decoration pretreatment step: The decorative film layer with flame-retardant properties is pre-placed in the cavity of the mold unit 1 through the film positioning and conveying unit 2, and the cavity is evacuated through the positive and negative pressure control unit 4 so that the decorative film layer is tightly adsorbed on the mold surface. S2: Substrate filling and molding step: Flame-retardant composite material substrate is injected or pressed into the mold cavity with a pre-formed decorative film layer through the substrate feeding unit 3; S3: In-mold curing bonding step: The mold temperature is precisely controlled by the heating and temperature control unit 5, and the positive and negative pressure control unit 4 switches to a positive pressure environment, so that the flame-retardant composite material substrate flows, fills and cures in the mold. Temperature and pressure are used to make the bonding surface between the substrate and the decorative film layer undergo molecular-level melting or cross-linking reaction, forming an integrated bonding interface without adhesive layer. S4: Demolding step: Open the mold and remove the flame-retardant composite material cabinet component with a permanent decorative protective layer on the surface.

[0032] In this embodiment, in S1, the decorative film layer is a multi-layer composite structure, which includes: a scratch-resistant transparent flame-retardant layer on the outer surface, a pattern printing layer in the middle, and a functional hot-melt bonding layer on the inner surface; the melting point of the material of the functional hot-melt bonding layer is lower than the curing temperature of the flame-retardant composite material substrate.

[0033] Furthermore, any content not described in detail in this specification is existing technology known to those skilled in the art.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0035] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A bonding and molding system for flame-retardant composite materials used in integrated cabinets, characterized in that: It includes a mold unit (1), a diaphragm positioning and conveying unit (2), a substrate feeding unit (3), a positive and negative pressure control unit (4), a heating and temperature control unit (5), and an intelligent control unit (6). The intelligent control unit (6) is bidirectionally connected to the diaphragm positioning and conveying unit (2), the substrate feeding unit (3), the positive and negative pressure control unit (4), and the heating and temperature control unit (5). The diaphragm positioning and conveying unit (2), the substrate feeding unit (3), the positive and negative pressure control unit (4), and the heating and temperature control unit (5) are bidirectionally connected to the mold unit (1). The diaphragm positioning and conveying unit (2) is used to accurately convey and fix the decorative film layer with flame-retardant properties into the cavity of the mold unit (1), so that the decorative surface of the decorative film layer faces the surface of the mold cavity and the bonding surface faces the inside of the cavity; The positive and negative pressure control unit (4) is connected to the mold unit (1) and is used to selectively establish a negative pressure environment or a positive pressure environment in the cavity at different stages of the molding process, so as to achieve precise adsorption of the decorative film layer and compaction of the substrate respectively.

2. The bonding and molding system for the flame-retardant composite material of the integrated cabinet according to claim 1, characterized in that: The positive and negative pressure control unit (4) operates as follows: During the pre-positioning stage of the decorative film layer, the mold cavity is evacuated to ensure that the decorative film layer is tightly adsorbed onto the surface of the mold cavity, preventing the film from shifting when the substrate is injected. During the substrate filling and curing stage, a positive pressure environment is switched to compact the substrate and promote molecular-level melting or cross-linking reactions at the interface between the substrate and the decorative film layer.

3. The bonding and molding system for the flame-retardant composite material of the integrated cabinet according to claim 1, characterized in that: The membrane positioning and conveying unit (2) and the mold unit (1) are further provided with a surface activation treatment unit. The surface activation treatment unit is a low-temperature plasma generator, which is located between the membrane positioning and conveying unit (2) and the mold unit (1) and at the output end of the substrate feeding unit (3). It is used to perform online activation treatment on the bonding surface of the decorative film layer and the surface of the flame-retardant composite material substrate before the substrate is filled, so as to introduce active groups to improve the interfacial bonding strength.

4. The bonding and molding system for the flame-retardant composite material of the integrated cabinet according to claim 1, characterized in that: The substrate feeding unit (3) is a multi-layer co-injection or co-pressure feeding device used to provide flame-retardant composite materials with gradient functions. After molding, the material forms a resin-rich dense surface layer near the decorative film layer and a lightweight reinforcing layer inside.

5. The bonding and molding system for the integral cabinet flame-retardant composite material according to claim 1, characterized in that: The mold unit (1) integrates a near-infrared spectral sensor, which is connected to the intelligent control unit (6) for online detection of the curing degree of the bonding interface. The intelligent control unit (6) automatically adjusts the process parameters of the next molding cycle according to the detection results.

6. The bonding and molding system for the flame-retardant composite material of the integrated cabinet according to claim 1, characterized in that: The mold unit (1) is a resin transfer molding mold or compression molding mold suitable for irregular curved surfaces or deep cavity structures; the decorative film layer transported by the diaphragm positioning and conveying unit (2) is a highly ductile oriented stretch film.

7. A bonding and molding system for flame-retardant composite materials for integrated cabinets, employing the production method of flame-retardant composite materials for integrated cabinets as described in any one of claims 1-6, characterized in that: Includes the following steps: S1: In-mold decoration pretreatment steps: The decorative film layer with flame-retardant properties is pre-placed in the cavity of the mold unit (1) through the film positioning and conveying unit (2), and the cavity is evacuated through the positive and negative pressure control unit (4) so ​​that the decorative film layer is tightly adsorbed on the mold surface. S2: Substrate filling and molding step: Flame-retardant composite material substrate is injected or pressed into the mold cavity with the decorative film layer through the substrate feeding unit (3); S3: In-mold curing bonding step: The mold temperature is precisely controlled by the heating and temperature control unit (5), and the positive and negative pressure control unit (4) switches to a positive pressure environment, so that the flame-retardant composite material substrate flows, fills and cures in the mold, and the temperature and pressure are used to make the bonding surface of the substrate and the decorative film layer undergo molecular-level melting or cross-linking reaction to form an integrated bonding interface without adhesive layer. S4: Demolding step: Open the mold and remove the flame-retardant composite material cabinet component with a permanent decorative protective layer on the surface.

8. The bonding and molding system for the flame-retardant composite material of the integrated cabinet according to claim 7, characterized in that: In step S1, the decorative film layer is a multi-layer composite structure, comprising: a scratch-resistant transparent flame-retardant layer on the outer surface, a pattern printing layer in the middle, and a functional hot-melt bonding layer on the inner surface; the melting point of the material of the functional hot-melt bonding layer is lower than the curing temperature of the flame-retardant composite material substrate.

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