Process for manufacturing one-piece die-cast aluminum alloy door and window

Abstract

The application discloses a manufacturing process of integrally die-casting aluminum alloy doors and windows, which comprises the following steps: S10, melting aluminum alloy ingot; S20, pressurizing the aluminum liquid into a mold cavity to form and solidify and cool, and taking out to form the inner frame, the outer frame, the inner sash and the outer sash of the blank structure; S30, trimming and correcting; S40, milling the inner frame and the outer frame; S50, placing the inner frame, the outer frame, the inner sash and the outer sash in an electrolyte solution respectively, and applying an external current to form an oxide film; S60, spraying treatment is conducted on the inner frame, the outer frame, the inner sash and the outer sash to form a decorative layer; S70, the inner frame and the outer frame, the inner sash and the outer sash are respectively clamped into a mold, high-pressure injection of heat insulation glue is conducted between the inner frame and the outer frame and between the inner sash and the outer sash respectively, and then solidification is conducted to form the window frame heat insulation body and the window sash heat insulation body, and the inner frame, the window frame heat insulation body and the outer frame jointly form a window frame, and the inner sash, the window sash heat insulation body and the outer sash jointly form a window sash; the manufacturing process can improve the quality and reliability of the aluminum alloy doors and windows.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, specifically to the manufacturing process of one-piece die-cast aluminum alloy doors and windows. Background Technology

[0002] Currently, the traditional door and window manufacturing process involves first ordering raw aluminum profiles from an aluminum alloy profile manufacturer. The manufacturer then purchases aluminum ingots from external suppliers, and the profiles undergo a series of complex processes, including aluminum rod production, extrusion molding, and the insertion of thermal break strips, to assemble the aluminum alloy profiles. The door and window manufacturer then processes these profiles through cutting, milling, and drilling before finally assembling them into finished doors and windows. This traditional manufacturing process has the following problems: 1. Long production cycle: Due to the need for multiple production and processing stages, the entire production cycle is relatively long, which cannot meet the demand for rapid delivery.

[0003] 2. Multiple production stages: The production process involves many stages, which increases the difficulty of management and coordination and can easily lead to quality problems.

[0004] 3. Risk of water leakage: The window frame and sash are assembled using a multi-connector assembly process with waterproof adhesive. Although this can provide a certain degree of waterproofing, there is still a risk of water leakage during long-term use.

[0005] 4. Height difference between gaps and joints: Due to limitations in the assembly process, there are height differences between the gaps and joints between the window frame and the window sash, which affects the aesthetics and sealing performance of the doors and windows.

[0006] 5. Unstable assembly quality: The use of multiple connectors and waterproof adhesive increases the difficulty and uncertainty of assembly, resulting in unstable assembly quality and problems such as loosening and deformation.

[0007] 6. Large geometric dimension errors: Geometric dimension errors are prone to occur during processing such as cutting and milling, which affects the installation and use of doors and windows.

[0008] 7. Poor interchangeability: Due to errors and uncertainties in the production process, there may be differences in size and shape between doors and windows produced in different batches, resulting in poor interchangeability and increasing the difficulty of subsequent maintenance and replacement. Summary of the Invention

[0009] In view of this, the present invention proposes a manufacturing process for integral die-cast aluminum alloy doors and windows to improve the quality and reliability of aluminum alloy doors and windows.

[0010] To achieve the above objectives, the present invention employs the following process: The manufacturing process of one-piece die-cast aluminum alloy doors and windows includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660℃-710℃; S20. Molten aluminum is injected into the mold cavity through a vacuum die casting machine to form and solidify and cool. After being removed, it forms a blank structure of inner frame, outer frame, inner fan and outer fan. S30. Perform edge trimming and correction; S40. Use a milling machine to mill grooves on the inner frame to form sound insulation strip installation grooves, heat insulation strip reinforcement grooves and hardware installation holes; mill grooves on the outer frame to form heat insulation strip reinforcement grooves and hardware installation holes. S50. Place the inner frame, outer frame, inner fan and outer fan in an electrolyte solution respectively, and apply an external current to form an oxide film on the surface of the inner frame, outer frame, inner fan and outer fan. S60. Spray coating is applied to the surfaces of the inner frame, outer frame, inner fan, and outer fan to form a decorative layer; S70. Insert the inner frame and outer frame, and the inner sash and outer sash into the mold respectively. At an ambient temperature of 24℃-28℃, inject heat insulation adhesive under high pressure between the inner frame and outer frame, and between the inner sash and outer sash, and let it solidify to form a window frame heat insulation body and a window sash heat insulation body. The inner frame, the window frame heat insulation body and the outer frame together constitute the window frame, and the inner sash, the window sash heat insulation body and the outer sash together constitute the window sash. S80. Install the frame sealant strip in the mounting groove of the sound insulation sealant strip in the window frame; S90. Install glass inside the window sash; S100, quality inspection, packaging.

[0011] To better implement the above technical solution, optionally, it also includes S31, using blue light to inspect the inner frame, outer frame, inner fan, and outer fan of the blank structure to determine whether there are defects such as cracks.

[0012] Optionally, it also includes S81, which requires coded traceability codes for window frames and window sashes; Optionally, in S60, the decorative layers of the window frame and window sash are the same color or different colors.

[0013] Optionally, in S70, the ambient temperature is 26°C.

[0014] The beneficial effects of this invention are: This invention relates to a manufacturing process for integrated die-cast aluminum alloy doors and windows. The integrated aluminum alloy doors and windows utilize a one-piece die-cast structure for both the inner and outer frames, eliminating the need for aluminum rods and extrusion processes. This significantly shortens the production cycle and improves strength, sound insulation, and thermal insulation performance. Furthermore, the elimination of frame assembly eliminates the problem of water leakage between the inner and outer frames. The error rate for mass-produced windows of the same type is almost zero, eliminating the need for conversion frames and reducing assembly steps. This improves product consistency and interchangeability, and generates no aluminum alloy waste. In addition, the use of high-pressure injection of thermal insulation adhesive, which solidifies after curing, connects the inner and outer frames, as well as the inner and outer sashes, resulting in superior overall integrity, waterproofing, and strength of the window frame and sash.

[0015] The integrated die-cast aluminum alloy doors and windows manufactured using the process described in this invention produce doors and windows of higher quality and with less error. Attached Figure Description

[0016] Figure 1 This is a three-dimensional schematic diagram of the window frame in an embodiment of the present invention; Figure 2 yes Figure 1 A schematic diagram of the decomposition process; Figure 3 This is a three-dimensional schematic diagram of the fan-shaped window in an embodiment of the present invention; Figure 4 yes Figure 3 A schematic diagram of the decomposition process; Figure label: Inner frame 10, sound insulation strip mounting groove 101, heat insulation strip reinforcement groove milling 102, hardware mounting hole 103, window frame heat insulation body 20, outer frame 30, inner sash 40, window sash heat insulation body 50, outer sash 60. Detailed Implementation

[0017] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Identical components are indicated by the same reference numerals.

[0018] Please see Figures 1-4 This invention discloses a manufacturing process for integral die-cast aluminum alloy doors and windows. Example

[0019] The manufacturing process of one-piece die-cast aluminum alloy doors and windows includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660°C; S20. Molten aluminum is injected into the mold cavity through a vacuum die casting machine to form and solidify and cool. S30. After molding, the parts are removed and trimmed and corrected by the mold to form independent inner frame 10, outer frame 30, inner fan 40 and outer fan 60. S40. Use a milling machine to mill grooves in the inner frame 10 to form sound insulation strip mounting groove 101, heat insulation strip reinforcement groove 102 and hardware mounting hole 103. Use a milling machine to mill grooves in the outer frame 30 to form heat insulation strip reinforcement groove 102 and hardware mounting hole 103. S50. Place the inner frame 10 and the outer frame 30 in an electrolyte solution, and apply an external current to form an oxide film on the surface of the inner frame 10 and the outer frame 30. S60. Spray coating is applied to the surfaces of the inner frame 10, outer frame 30, inner fan 40, and outer fan 60 to form a decorative layer. S70. Insert the inner frame 10 and outer frame 30, and the inner sash 40 and outer sash 60 into the mold respectively. At an ambient temperature of 24℃-28℃, inject heat insulation adhesive under high pressure between the inner frame 10 and outer frame 30 and between the inner sash 40 and outer sash 60 respectively, and then solidify to form the window frame and window sash. S80. Install the frame sealant strip in the soundproof sealant strip installation groove 101 of the window frame; S90. Install glass inside the window sash; S100, quality inspection, packaging.

[0020] In an embodiment of the present invention, S31 is further included: after removing the inner frame 10, outer frame 30, inner fan 40 and outer fan 60, blue light is used to detect whether there are cracks. The inner frame 10, outer frame 30, inner fan 40 and outer fan 60 with cracks are removed in this step.

[0021] In embodiments of the present invention, S81 is also included, where traceability codes for the window frame and window sash are applied so that subsequent operators can obtain information about the window frame and window sash.

[0022] In an embodiment of the present invention, in S60, the decorative layers of the window frame and the window sash are the same color or different colors.

[0023] In an embodiment of the present invention, in S70, the ambient temperature is 26°C. Example

[0024] The manufacturing process of one-piece die-cast aluminum alloy doors and windows includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 680°C; S20. Molten aluminum is injected into the mold cavity through a vacuum die casting machine to form and solidify and cool. S30. After molding, the parts are removed and trimmed and corrected by the mold to form independent inner frame 10, outer frame 30, inner fan 40 and outer fan 60. S40. Use a milling machine to mill grooves in the inner frame 10 to form sound insulation strip mounting groove 101, heat insulation strip reinforcement groove 102 and hardware mounting hole 103. Use a milling machine to mill grooves in the outer frame 30 to form heat insulation strip reinforcement groove 102 and hardware mounting hole 103. S50. Place the inner frame 10 and the outer frame 30 in an electrolyte solution, and apply an external current to form an oxide film on the surface of the inner frame 10 and the outer frame 30. S60. Spray coating is applied to the surfaces of the inner frame 10, outer frame 30, inner fan 40, and outer fan 60 to form a decorative layer. S70. Insert the inner frame 10 and outer frame 30, and the inner sash 40 and outer sash 60 into the mold respectively. At an ambient temperature of 24℃-28℃, inject heat insulation adhesive under high pressure between the inner frame 10 and outer frame 30 and between the inner sash 40 and outer sash 60 respectively, and then solidify to form the window frame and window sash. S80. Install the frame sealant strip in the soundproof sealant strip installation groove 101 of the window frame; S90. Install glass inside the window sash; S100, quality inspection, packaging.

[0025] In an embodiment of the present invention, S31 is further included: after removing the inner frame 10, outer frame 30, inner fan 40 and outer fan 60, blue light is used to detect whether there are cracks. The inner frame 10, outer frame 30, inner fan 40 and outer fan 60 with cracks are removed in this step.

[0026] In embodiments of the present invention, S81 is also included, where traceability codes for the window frame and window sash are applied so that subsequent operators can obtain information about the window frame and window sash.

[0027] In an embodiment of the present invention, in S60, the decorative layers of the window frame and the window sash are the same color or different colors.

[0028] In an embodiment of the present invention, in S70, the ambient temperature is 26°C. Example

[0029] The manufacturing process of one-piece die-cast aluminum alloy doors and windows includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 710°C; S20. Molten aluminum is injected into the mold cavity through a vacuum die casting machine to form and solidify and cool. S30. After molding, the parts are removed and trimmed and corrected by the mold to form independent inner frame 10, outer frame 30, inner fan 40 and outer fan 60. S40. Use a milling machine to mill grooves in the inner frame 10 to form sound insulation strip mounting groove 101, heat insulation strip reinforcement groove 102 and hardware mounting hole 103. Use a milling machine to mill grooves in the outer frame 30 to form heat insulation strip reinforcement groove 102 and hardware mounting hole 103. S50. Place the inner frame 10 and the outer frame 30 in an electrolyte solution, and apply an external current to form an oxide film on the surface of the inner frame 10 and the outer frame 30. S60. Spray coating is applied to the surfaces of the inner frame 10, outer frame 30, inner fan 40, and outer fan 60 to form a decorative layer. S70. Insert the inner frame 10 and outer frame 30, and the inner sash 40 and outer sash 60 into the mold respectively. At an ambient temperature of 24℃-28℃, inject heat insulation adhesive under high pressure between the inner frame 10 and outer frame 30 and between the inner sash 40 and outer sash 60 respectively, and then solidify to form the window frame and window sash. S80. Install the frame sealant strip in the soundproof sealant strip installation groove 101 of the window frame; S90. Install glass inside the window sash; S100, quality inspection, packaging.

[0030] In an embodiment of the present invention, S31 is further included: after removing the inner frame 10, outer frame 30, inner fan 40 and outer fan 60, blue light is used to detect whether there are cracks. The inner frame 10, outer frame 30, inner fan 40 and outer fan 60 with cracks are removed in this step.

[0031] In embodiments of the present invention, S81 is also included, where traceability codes for the window frame and window sash are applied so that subsequent operators can obtain information about the window frame and window sash.

[0032] In an embodiment of the present invention, in S60, the decorative layers of the window frame and the window sash are the same color or different colors.

[0033] In an embodiment of the present invention, in S70, the ambient temperature is 26°C.

[0034] The beneficial effects of Examples 1-3 are as follows: This invention relates to a manufacturing process for integrated die-cast aluminum alloy doors and windows. The integrated aluminum alloy doors and windows utilize a one-piece die-cast structure for the inner frame 10 and outer frame 30, eliminating the need for aluminum rods and extrusion processes. This significantly shortens the production cycle and improves strength, sound insulation, and thermal insulation performance. Furthermore, the elimination of frame assembly eliminates the problem of water leakage inherent in the inner frame 10 and outer frame 30. The error in mass-produced windows of the same type is virtually zero, eliminating the need for conversion frames and reducing assembly steps. This improves product consistency and interchangeability, and generates no aluminum alloy waste. In addition, the use of high-pressure injection thermal insulation adhesive, which solidifies after curing, connects the inner frame 10 and outer frame 30, and the inner sash 40 and outer sash 60, resulting in superior integrity, waterproofing, and strength for the window frame and sash.

[0035] The following table compares the product quality of window frames and sashes manufactured using this invention with that of existing standardized products:

[0036] As can be seen from the above, the integrated aluminum alloy doors and windows manufactured by the integrated die-casting process of the present invention have higher quality and smaller errors.

[0037] The technical solution of the present invention has been described in detail above with reference to specific embodiments. The specific embodiments described are used to help understand the concept of the present invention. Derivations and modifications made by those skilled in the art based on the specific embodiments of the present invention also fall within the scope of protection of the present invention.

Claims

1. The manufacturing process of one-piece die-cast aluminum alloy doors and windows, characterized in that, Includes the following steps: S10. Melt the heat-free aluminum alloy ingot and maintain it at 660℃-710℃; S20. The aluminum liquid is injected into the mold cavity through a vacuum die casting machine to form and solidify and cool. After being taken out, it forms an inner frame (10), an outer frame (30), an inner fan (40), and an outer fan (60) of a blank structure. S30. Perform edge trimming and correction; S40. Use a milling machine to mill grooves in the inner frame (10) to form a sound insulation strip mounting groove (101), a heat insulation strip reinforcement groove (102) and a hardware mounting hole (103). Use a milling machine to mill grooves in the outer frame (30) to form a heat insulation strip reinforcement groove (102) and a hardware mounting hole (103). S50. Place the inner frame (10), outer frame (30), inner fan (40) and outer fan (60) in an electrolyte solution, and apply an external current to form an oxide film on the surface of the inner frame (10), outer frame (30), inner fan (40) and outer fan (60). S60. Spray coating is applied to the surfaces of the inner frame (10), outer frame (30), inner fan (40), and outer fan (60) to form a decorative layer; S70. Insert the inner frame (10) and outer frame (30), and the inner sash (40) and outer sash (60) into the mold respectively. At an ambient temperature of 24℃-28℃, inject heat insulation adhesive under high pressure between the inner frame (10) and outer frame (30) and between the inner sash (40) and outer sash (60) respectively, and solidify to form a window frame heat insulation body (20) and a window sash heat insulation body (50). The inner frame (10), the window frame heat insulation body (20) and the outer frame (30) together constitute the window frame, and the inner sash (40), the window sash heat insulation body (50) and the outer sash (60) together constitute the window sash. S80. Install the frame sealant strip in the soundproof sealant strip mounting groove (101) of the window frame; S90. Install glass inside the window sash; S100, quality inspection, packaging.

2. The manufacturing process of the integral die-cast aluminum alloy doors and windows according to claim 1, characterized in that, It also includes S31, using blue light to inspect the inner frame (10), outer frame (30), inner fan (40) and outer fan (60) of the blank structure to determine whether there are defects such as cracks.

3. The manufacturing process of the integral die-cast aluminum alloy doors and windows according to claim 1, characterized in that, It also includes S81, which requires coded traceability codes for window frames and sashes.

4. The manufacturing process of the integral die-cast aluminum alloy doors and windows according to claim 1, characterized in that, In S60, the decorative layers of the window frame and window sash are either the same color or different colors.

5. The manufacturing process of the integral die-cast aluminum alloy doors and windows according to claim 1, characterized in that, In S70, the ambient temperature is 26°C.

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