A synchronous register hot-press forming method of double-faced veneer thermal insulation composite board

Abstract

The application discloses a synchronous register hot-press forming method of double-faced veneer thermal insulation composite board, relates to the hot-press forming technical field of decorative composite board, and comprises the following steps: firstly, the upper decorative layer, the thermal insulation core material slab and the lower decorative layer are cooperatively fed, wet heat initial state is symmetrized, the core material state is identified, and the closed stroke is pre-compensated, so that the prescription package of the present board is formed; then, in the stage that the press is closed at low pressure and the resin is not melted, the phase constraint mechanism is connected with the edge alignment reference of the upper and lower decorative layers, so that the phase locking state between the upper decorative layer, the lower decorative layer and the press mold relief is established; then, in the phase locking state maintaining period, the upper press plate and the lower press plate are controlled to execute asymmetric thermal force differential time sequence according to the core material state, so that the upper and lower resins enter the corresponding viscosity window; finally, the phase constraint mechanism is controlled to be separated from the edge alignment reference before pressure rising and solidification, and the pressure rising and solidification and the alignment result feedback are completed. The method can reduce the phase drift risk of the soft thermal insulation core material in the hot-press process.

Description

Technical Field

[0001] This invention relates to the field of hot pressing molding technology for decorative composite panels, specifically a method for simultaneous hot pressing molding of double-sided thermal insulation composite panels. Background Technology

[0002] Hot pressing of decorative panels is commonly used for interior wall panels, door panels, furniture panels, integrated insulation and decoration panels, and prefabricated building cladding panels. In actual production, to balance insulation, lightweighting, and surface decoration, core materials such as foamed polymers, phenolic resins, and mineral wool are typically laminated with decorative paper, PVC film, impregnated film, or wear-resistant layers. The adhesive layer is then softened, impregnated, and cured using a hot press. Simultaneously, embossed steel plates or die-cutting techniques are used to create wood grain, stone grain, or fabric textures on the surface. In contrast, the printing pattern required in synchronous pattern matching processes must be matched to its relief. Most existing production lines can control the process around feeding correction, color mark detection, embossed plate positioning, hot pressing lamination, and cutting and grooving. For example, in online synchronous pattern matching co-extrusion flooring processes, a calender is often used in conjunction with synchronous pattern matching to roll-press the decorative layer pattern of the flooring.

[0003] Chinese patent document CN112095967A discloses a multi-layer synchronous matching pattern molded rounded edge PVC panel. The panel body includes, from top to bottom, a UV paint layer, a PVC wear-resistant layer, a PVC patterned film layer, a PVC substrate board, and a PVC base layer. Its surface has a synchronous matching pattern simulated three-dimensional texture, and it has rounded edges and a locking structure around the perimeter. It can be used as a decorative panel for flooring, wall panels, and furniture panels. The process employs a two-stage hot-press composite synchronous patterned rounded edge process: A padding layer, PVC substrate board, and PVC patterned film are sequentially laid on the press tray. After a single hot-press composite and cold-press forming process, a synchronously patterned rounded edge PVC decorative panel is created. Then, holes are punched at corresponding positions on the edges of the decorative panel and the multi-layer synchronously patterned rounded edge embossed board. It is then re-layered with the PVC base material, release film, and embossed board, and positioned through pin holes for a second hot-press composite and a second cold-press forming. Following this, UV paint is applied, UV curing occurs, followed by tempering, cooling, CNC cutting or modular positioning cutting, grooving, and packaging to finally obtain the finished product. Thus, the embossed board, patterned film, pin hole positioning, and second hot-press composite process ensure that the surface texture of the PVC panel corresponds to the embossed shape.

[0004] The aforementioned existing technologies can effectively serve the synchronous pattern matching and rounded edge forming of PVC substrate panels, but they still have some shortcomings in double-sided insulated composite panels. For example, the middle layer of double-sided insulated composite panels is usually a thick lightweight insulation core material, whose thermal conductivity, compression resilience, and local thickness tolerance are significantly different from those of PVC substrate panels; moreover, the upper and lower decorative layers are affected by the softening of the adhesive layer, compression of the core material, surface temperature transfer, and moisture migration during hot pressing. If one side enters a state of lower flow resistance first, the pattern layer may undergo slight displacement due to adhesive layer shearing and core material rebound. The pin hole positioning and secondary hot-pressing composite mainly rely on the pre-formed decorative panel and the edge holes of the embossed board for positioning. The process mechanism assumes that the positioned layer has relatively stable dimensions and support rigidity. It does not specifically address the double-sided phase drift problem of the sandwich soft insulation layer during the hot-pressing closing process. If this type of process is directly applied to double-sided insulation composite boards, it is easy to cause problems such as inconsistent alignment of the upper and lower surface patterns, increased cutting allowance after hot pressing, local adhesive layer dragging, stress concentration on the board edge, and reduced batch stability.

[0005] Therefore, there is still a need in this field to solve how to maintain the patterns on the top and bottom surfaces of a double-sided thermal insulation composite board in a stable and controllable synchronous matching manner within the same hot-pressing cycle when the sandwich insulation material is involved in hot pressing. Summary of the Invention

[0006] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a synchronous hot-pressing method for double-sided thermal insulation composite panels. First, a single-panel formula package is formed. Then, during the low-pressure closure of the press and before the resin melts, a phase-constraining mechanism engages with the edge alignment references of the upper and lower decorative layers to establish a phase-locked state between the upper and lower decorative layers and the molded relief. Subsequently, while maintaining the phase-locked state, the upper and lower pressure plates are controlled to perform asymmetric thermo-differential timing according to the core material state, causing the upper and lower resins to enter the corresponding viscosity windows. Finally, before pressure-pressing and curing, the phase-constraining mechanism is controlled to disengage from the edge alignment references, and pressure-pressing and curing, along with alignment result feedback, are completed. This method can reduce the risk of phase drift in sandwich soft insulation core materials during hot pressing and solves the technical problems described in the background art.

[0007] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: A method for synchronous hot pressing of double-sided thermal insulation composite panels, wherein the press is controlled by a press control system, includes: Obtain the core material condition data and edge alignment reference information of the upper and lower decorative layers of the same stacked material. The core material condition data includes the core material type and core material thickness. The stacked material is controlled to enter the press, and the phase constraint mechanism is driven to apply phase constraint to the edge alignment reference during the low-pressure closing stage when the resin is not melted, so that the upper decorative layer, the lower decorative layer and the molded relief form a phase-locked state. During the phase-locked state, the upper and lower pressure plates are controlled to perform asymmetric thermo-differential timing based on the core material state data, and a low viscosity window state signal is generated when the upper and lower resins reach the preset low viscosity window. Based on the low viscosity window state signal, pressure state, temperature state, and viscosity state, the phase constraint mechanism is driven to disengage from the edge alignment reference before pressurization and curing, and the press is controlled to pressurize and cure.

[0008] Furthermore, after acquiring the core material status data, the press control system generates a plate identifier for the stacked material stack and writes the core material thickness, core material type, edge alignment reference information, and the low-pressure landing point of the press closing servo into the sheet prescription package. The press control system generates a pre-compensation amount for the closed stroke based on the core material thickness, and transmits the pre-compensation amount for the closed stroke to the low-pressure closing stage along with the board marking. When the pre-compensation amount for the closed stroke falls into the allowable window of the press closing servo, the low-pressure closing is executed. When it does not fall into the allowable window, the phase constraint action is stopped and the degraded board mark is output.

[0009] Furthermore, during the low-pressure closing phase, the press control system reads the phase constraint mechanism action pressure window, inlet temperature difference residual window, and locking window duration in this sheet prescription package, and reads the actual low-pressure landing point of the press closing servo. When the pressure, temperature, stroke, and timing states all enter the corresponding window, an extension command is sent to the phase constraint mechanism; when any state does not enter the corresponding window, low pressure is maintained and pressure increase for curing is prohibited.

[0010] Furthermore, the phase constraint mechanism includes at least one phase locking pin, and the edge alignment reference includes a mechanical engagement slot disposed within the trimming redundancy band; the phase locking pin has an asymmetrical cross section, and the mechanical engagement slot has a unidirectional guide edge corresponding to the asymmetrical cross section; the edge region of the embossed relief is provided with a pressure buffer band surrounding the phase locking pin. When the phase lock pin sends back a signal indicating it is in position, it is allowed to enter the asymmetric thermal differential timing sequence. When it does not send back a signal indicating it is in position, the phase lock pin retracts and an engagement failure flag is output.

[0011] Furthermore, the phase constraint mechanism is a vacuum adsorption type phase constraint mechanism, and the edge alignment reference includes a microporous strip set along the edges of the upper and lower decorative layers. The press control system opens the vacuum channel at the edge of the pressing template during the low-pressure closing stage, so that the microporous strip is attached to the edge reference surface of the pressing mold relief. When the vacuum negative pressure reaches the adsorption window, the phase lock state is maintained. When the vacuum negative pressure does not reach the adsorption window, the pressure increase is stopped and an adsorption abnormality mark is output.

[0012] Furthermore, when executing the asymmetric thermo-differential timing sequence, the press control system reads the heating zone configuration of the upper and lower pressure plates; When both the upper and lower pressure plates have independent heating zones, the set temperatures for the upper and lower pressure plates are written respectively; when at least one pressure plate is not configured with an independent heating zone, the same reference hot pressing temperature is maintained, and differential control is applied to the contact holding time of the upper and lower pressure plates.

[0013] Furthermore, the press control system reads the actual temperature, pressure, and viscosity of the upper and lower pressure plates during the phase-locked state; when a low viscosity window state signal is generated within the predetermined holding period of the phase-locked state, disengagement is performed according to the pressure, temperature, and viscosity states. When the low viscosity window state signal is not generated within the predetermined holding period, the phase constraint mechanism is maintained and the process enters the degraded pressure boosting curing path, while the board identification is written to the abnormal process log.

[0014] Furthermore, the action command message sent by the press control system to the phase constraint mechanism includes the plate identifier, process stage identifier, phase constraint mechanism number, action direction, target stroke, action pressure window, allowable action time, and verification field. The feedback message returned by the phase constraint mechanism includes the plate identifier, phase constraint mechanism number, positioning mark, position deviation, and fault code. When the plate identifiers of the two messages are consistent, the feedback message is adopted; when they are inconsistent, the feedback message is discarded and the current pressure state is maintained.

[0015] Furthermore, after sending the action command message, the press control system generates a differential control setting message, which includes plate identifier, upper pressure plate setting value, lower pressure plate setting value, differential mode field, phase lock status flag, low viscosity window status signal, and effective cycle time field. When the phase lock status flag is valid, the differential control setting message is written to the pressure plate controller; when the phase lock status flag is invalid, the differential control setting message is not written and the current pressure status is maintained.

[0016] Furthermore, after the press curing is completed, the press control system outputs process data logs and human-machine interface status; the process data logs include board identification, low-pressure lockout stage timestamp, differential control setting message, action command message, feedback message, press curing start time, and abnormal flags; The human-machine interface displays the status in sequence as standby, low-pressure lock, differential heating, mechanism disengagement, pressure boosting and curing, and abnormal diagnosis. When the abnormal marker is empty, the pressure boosting and curing completion status is displayed; when the abnormal marker is not empty, the abnormal diagnosis status is displayed.

[0017] (III) Beneficial Effects This invention provides a method for simultaneous hot-pressing of double-sided thermal insulation composite panels, which has the following advantages: By coordinating the feeding of the upper decorative layer, the insulation core material blank and the lower decorative layer before pressing, the initial state of damp heat is symmetrical, the core material state is identified and the closed stroke is pre-compensated, so that the stacked material entering the press has a more consistent initial state of material and closed reference, reducing the initial phase shift caused by the difference in damp heat of the coil, the fluctuation of the core material thickness and the deviation of the pressing point.

[0018] When the press is closed at low pressure and the resin has not melted, the phase constraint mechanism engages with the alignment reference of the upper and lower decorative layers. This establishes a phase locking relationship between the upper and lower decorative layers and the molded relief before the adhesive layer flows, thus avoiding the problem of uncontrolled slippage in the press caused by simply relying on feeding correction.

[0019] During the phase-locked state, the upper and lower pressure plates are controlled to perform asymmetric thermo-differential timing based on the core material's state. This ensures that the softening process of the upper and lower resins matches the heat transfer and compression rebound characteristics of the core material, reducing the risk of pattern layer drift caused by resin flowing on one side first. The phase constraint mechanism is disengaged within a window where the resin has acquired viscous bearing capacity but before pressurization and curing have begun, smoothly transitioning from mechanical locking to resin viscous locking. This prevents phase drift due to premature disengagement and damage around the slots due to delayed disengagement.

[0020] Through the continuous connection of low-pressure locking, differential thermal control, pressure release, and alignment result feedback, the same board exhibits a closed-loop structure in terms of material state, press operation, and subsequent formula correction. This facilitates the simultaneous double-sided matching production under different core material types, different decorative layer batches, and different press operating conditions. The phase constraint mechanism, in conjunction with the edge alignment reference, pressure buffer structure, and abnormal flow diversion mechanism, ensures that the alignment action mainly occurs in the cutting redundancy area and the controllable pressure stage, which not only guarantees the controllability of the matching position but also reduces interference with the visible decorative surface of the finished product. Attached Figure Description

[0021] Figure 1 This is a flowchart illustrating the overall process of the synchronous hot-pressing molding method for double-sided thermal insulation composite panels according to the present invention. Figure 2 This is a schematic diagram of the multi-source collaborative feeding and the generation of the sheet prescription package according to the present invention; Figure 3 This is a schematic diagram of the low-pressure phase-locking station of the present invention; Figure 4 This is a partially enlarged view of the phase locking pin, mechanical engagement reference, and pressure buffer band of the present invention; Figure 5 This is a timing diagram of the low-pressure locking entrance gate control and phase locking operation of the present invention; Figure 6 This is a schematic diagram illustrating the asymmetric thermodynamic differential control and synchronous arrival of low viscosity according to the present invention; Figure 7 This is a schematic diagram of the phase constraint mechanism of the present invention to avoid separation and pressure-pressurization curing relay; Figure 8 This is a schematic diagram of the edge visual detection and prescription table recursive correction of the present invention. Detailed Implementation

[0022] 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 skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Please see Figures 1-8 This invention provides a method for simultaneous hot-pressing of double-sided thermal insulation composite panels, comprising: Step 1: Before the upper decorative layer, the insulation core material blank, and the lower decorative layer enter the press for low-pressure closure, generate a stack of materials with a symmetrical humid and hot state, compensated closure stroke, and reusable in subsequent steps.

[0024] The pattern matching error of double-sided thermal insulation composite panels does not only occur at the moment the press closes, but is pre-existing in three types of initial deviations: First, the moisture content, surface temperature, and linear velocity of the upper and lower decorative layers are inconsistent, causing the same pattern to have different expansion and contraction trends before being heated and pressed; Second, the thickness and density of the insulation core material blank fluctuate along the batch, causing the actual compression amount to deviate when the press closes to the low-pressure phase lock position; Third, the production plan only gives the core material type, board specifications, and pattern matching accuracy level. If it is not converted into subsequent executable differential components, locking windows, and pin action sequences, steps two and three can only be performed based on experience, making it difficult to form a repeatable process chain.

[0025] Based on this, step one transforms the material preparation into a pre-process with state measurement, state shaping and prescription assembly, so that the material has boundary conditions that can be mechanically locked and thermally differentially utilized before entering the press.

[0026] After receiving the production plan, the production line controller first generates a panel identifier for this sheet and binds the upper decorative layer roll, the insulation core material blank, and the lower decorative layer roll to the same panel identifier. The upper and lower decorative layers, after being output from their independent material storage, do not directly enter the press but instead pass through the tension leveling section, the humidity and temperature conditioning channel, and the pre-pressing inspection section sequentially. The insulation core material blank is fed into the thickness measurement and identification section from the intermediate material channel to complete core material type identification, sheet-by-sheet thickness sensing, and density level confirmation. The main control PLC aggregates the above data to form four types of results: "decorative layer initial deviation," "core material thickness deviation," "closed stroke pre-compensation," and "sheet prescription package." The sheet prescription package enters the press inlet along with the stacked material stack and serves as the direct input for triggering low-pressure phase locking in step two and determining the differential polarity in step three.

[0027] The upper and lower decorative layers are each connected by independent humidity and temperature control channels. Each channel contains an inlet tension roller, a heat exchange section, a surface temperature detector, a near-infrared moisture content detector, and an outlet correction roller, all positioned along the feeding direction. The inlet tension roller is solely responsible for eliminating looseness in the roll material and does not alter the pattern phase. The heat exchange section uses a constant humidity airflow or a heat radiation plate to moderate the adhesive-backed and finished sides of the decorative layer. The outlet correction roller uses the edge alignment reference to ensure the pattern baseline remains straight before entering the lamination area.

[0028] For example, when the surface temperature of the upper decorative layer is higher than that of the lower decorative layer due to its proximity to the heat source, the upper channel reduces the proportion of hot air and prolongs the contact of the constant humidity airflow, while the lower channel maintains a gentle temperature rise. This ensures that the two decorative layers no longer respond to the same platen temperature at different shrinkage rates before entering the press. The result of this action is not simply heating or humidifying, but rather bringing the two-sided veneer materials to a common initial state that can withstand subsequent differential thermal control.

[0029] To disclose the method for determining this common initial state, the main control PLC first generates a moisture content difference based on the detection results at the outlet of the humidity and temperature control channel. Temperature difference with decorative layer Then, the initial deviation of the decorative layer is used. For the The difference between the upper and lower decorative layers of the sheet was normalized and characterized: Among them, the difference in moisture content Used to determine the difference in moisture expansion between the upper and lower decorative layers before pressing, and the moisture content of the upper decorative layer. With the moisture content of the lower decorative layer Data collected by a near-infrared moisture detector; temperature difference in the decorative layer. Used to determine the difference in thermal expansion and contraction between the upper and lower decorative layers before pressing; surface temperature of the upper decorative layer. With the surface temperature of the lower decorative layer Data is collected by an infrared thermometer or a contact temperature sensor. Among them, the initial state deviation of the decorative layer The value range is from 0 to above 1, used to determine whether the double decorative layers have completed symmetry before pressing; the moisture content of the upper decorative layer. and the moisture content of the lower decorative layer The value range is determined by the supply specifications of the decorative paper or finishing film, and is used to characterize the tendency for moisture expansion; allowable moisture content difference. Preferably, a value of no more than 0.2% is used to normalize the moisture content deviation; the surface temperature of the upper decorative layer. and the surface temperature of the lower decorative layer The value range is the controllable temperature range at the outlet of the humidity and temperature control channel, used to characterize the thermal expansion and contraction trend; the allowable temperature difference The preferred temperature range is no greater than 3°C, used to normalize the temperature deviation; the linear velocity of the upper decorative layer. and the linear velocity of the lower decorative layer The value range is set by the feed servo and is used to characterize the phase synchronization of the pattern reaching the overlapping area; allowable linear speed difference. Calculated from press cycle time and pattern pitch; moisture content weight Temperature weighting and line speed weight The values ​​range from 0 to 1, and the sum of the three is 1. They are used to allocate the influence of different decorative layer materials on the sensitivity of moisture expansion, thermal expansion and feeding error. The above weights are initialized by the first test record or historical qualified plate data and are kept consistent within the same decorative layer batch.

[0030] The dwell time in the humidity and temperature regulation channel is not based on a fixed cycle, but rather on the initial deviation of the decorative layer. Determined together with the measured difference between the upper and lower decorative layers: Among them, pre-symmetric residence time The value range is 30s to 90s, used to determine the residence time of the decorative layer in the humidity and temperature regulation channel; minimum residence time. To ensure sufficient initiation of moisture and heat exchange on the surface of the roll material; maximum residence time. Used to prevent excessive moisture absorption or overheating of the roll material; basic residence time Determined by the material formulation; moisture content correction factor and temperature correction factor The results were obtained by converting the moisture content response curve and outlet temperature response curve of the same batch of decorative layers under a fixed air volume, and were used to convert the moisture content difference and temperature difference into channel dwell compensation.

[0031] The above expressions for taking the minimum and maximum values ​​are disclosed as a saturation pruning rule, that is, when the computation time is lower than the minimum dwell time... Take the minimum dwell time When the calculation time is higher than the maximum dwell time Take the maximum dwell time .

[0032] When in use, when the upper and lower decorative layers enter the overlapping area, their edge alignment reference and pattern reference line are no longer pulled by the difference in the initial state of humidity and heat, thus providing a stable insertion object for the phase locking pin in step two; at the same time, the humidity and heat state of the two decorative layers is organized into the same evaluation caliber, so that when applying differential thermal control according to the core material type in step three, the difference of the decorative layer itself will not be misjudged as the differential demand caused by the core material.

[0033] Before entering the lamination area, the insulation core material slab passes through a core material identification gantry and a thickness measuring gantry. The core material identification gantry reads the batch barcode, core material type mark, or infrared spectral characteristics to classify the insulation core material slab into the formulation category such as expanded polystyrene, polyurethane, polyisocyanurate, phenolic, or mineral wool. The thickness measuring gantry uses laser displacement sensors or contact thickness measuring wheels arranged vertically to obtain no less than three measuring points along the width of the slab, and distinguishes and stores the edge warping points from the central pressure points.

[0034] For example, if the thickness of the middle part of a phenolic core board blank is higher than the nominal thickness of this batch, while the edge is still within the compressible range, the main control PLC does not directly reject the board. Instead, it converts the thickness deviation in the middle part into a pre-compensation amount for the press's closed stroke, so that when the press reaches the phase locking position in the low-pressure stage, the extension height of the pin mechanism is still in the same geometric window as the edge alignment reference.

[0035] Closed stroke pre-compensation amount The following values ​​are provided based on core material thickness deviation, core material density deviation, and compression modulus level: Among them, the closed-loop pre-compensation amount The value range is limited by the fine-tuning capability of the press servo stroke, and is used to correct the first... The closing point when the tension plate enters the low-pressure locking stage; the measured thickness of the core material. The value range for measuring the central bearing thickness of the gantry output is determined by the plate specifications; the nominal thickness of the core material... The thickness of the board as specified in the production plan; the actual measured density of the core material. The core material reference density can be calculated from weighing information and slab volume, or read from the batch density setting. The baseline value for the corresponding core material category in the prescription table; core material compression modulus. Obtained from a table based on core material type and density level; core material reference compressive modulus. Standard operating conditions for the same core material category; thickness compensation coefficient. The density compensation coefficient is determined by the press's no-load closure calibration and standard core material compression test. The modulus compensation coefficient is determined by fitting the closed-loop offset of different density grades of the same core material. The low-pressure closure curve of the first piece is determined by the corresponding compression modulus range. These three parameters represent the contributions of thickness, density, and compression modulus to the low-pressure closure point, respectively. When the measured density of the core material... or core material compression modulus When online measured values ​​are unavailable, the main control PLC uses the core material category. The corresponding prescription table baseline value, and in this prescription pack. The field is marked as the source of the table lookup.

[0036] If the closed stroke pre-compensation amount Upon entering the press servo's allow window, the main control PLC sends a stroke correction command for the current sheet to the closing servo. The command fields must include at least the sheet identifier, stroke correction value, effective cycle time, core material type, and checksum. Only after the closing servo returns an acceptance status is the stacked material allowed to enter the press inlet. (If the closing stroke pre-compensation amount...) If the window is exceeded, the main control PLC will not continue to execute the pin engagement preparation, but will instead mark the board as a degraded board and guide it to a separate processing path to prevent abnormal core material from pushing the phase locking pin to the wrong height.

[0037] When in use, the core material thickness and compression rebound are no longer considered as latent disturbances in step two, and a definite geometric relationship is formed between the low-pressure closed position of the press and the edge alignment reference; at the same time, the core material type and compensation amount are written into the sheet formulation package, so that step three can use the same core material state to calculate the differential thermodynamic time series.

[0038] After the double decorative layers have completed pre-symmetry and the insulation core material board blank has completed pre-compensation calculation, the main control PLC executes the prescription packaging in the stacking area. The upper decorative layer, insulation core material board blank, and lower decorative layer are stacked sequentially according to the surface orientation, adhesive layer orientation, and edge alignment reference orientation. The edge guide rulers on both sides of the stacking table only contact the cutting redundancy strip and do not compress the visible decorative area. The edge alignment reference of the upper decorative layer and the edge alignment reference of the lower decorative layer are roughly aligned on the stacking table. The roughly aligned stack is fed into the press inlet by the clamping feeding beam.

[0039] For example, if the alignment reference of the decorative layer edge is a combination of holes and slots, the upper and lower holes and slots only need to reach the range that the pin mechanism can capture on the stacking platform. It is not required to complete the final fine alignment in the feeding stage. The final fine alignment is completed by the phase locking pin in the low-pressure stage in step two, thereby avoiding the feeding servo from bearing too high positioning burden.

[0040] This prescription package The data is written to the main control PLC buffer in the form of a data frame and passed to subsequent steps along with the board identifier: Among them, this prescription pack For the first The process control set formed before the sheet enters the press is used to connect steps two through four; core material category Derived from the core material identification gantry, used to retrieve differential thermal prescriptions; closed-stroke pre-compensation amount. Derived from the aforementioned, used for press closure servo correction; target differential temperature. The values ​​are obtained by looking up a table or interpolating the core material type, density level, and compression modulus level, and are used for setting the differential between the upper and lower pressure plates in step three; window lock duration. This indicates the low-pressure phase lock holding time, used to control the phase constraint mechanism to maintain engagement during this phase. Pin extension pressure This indicates the pressure inlet that the phase constraint mechanism is allowed to extend in step two; the temperature difference stabilization time. This indicates the duration of residual inlet temperature difference within the allowable range, used to ensure that the upper and lower decorative layers do not initially slip due to uneven preheating when the pin extends; pin retraction pressure. This indicates the pressure inlet that allows the phase constraint mechanism to disengage in step four; retraction viscosity lower limit. With upper limit of shrinkage viscosity This is used to define a window where the decorative resin adhesive layer is in a position to receive the phase but has not yet cured to lock the phase constraint mechanism when it disengages. Each item in the above prescription package is generated from the material state or prescription table of this sheet and does not share temporary values ​​with other sheets.

[0041] Prescription package data frames are preferably sent via periodic communication between the production line main controller and the main control PLC. The communication fields include board identification, core material type, initial deviation of decorative layer, pre-compensation amount of closed stroke, target differential temperature, lock window duration, pin action pressure inlet, timestamp, and check code. When the check fails or the board identification is inconsistent, the feeding beam stops outside the press inlet, and the main control PLC re-requests the prescription package for that board to avoid mismatch between stacked material stacks and prescription packages.

[0042] As a parallel implementation, core material identification can be replaced by infrared spectroscopy identification instead of barcode reading, thickness measuring gantry can be replaced by a laser displacement sensor instead of a contact thickness measuring wheel, and humidity and temperature regulating channel can be replaced by a combination of a constant humidity airflow and a heat radiation plate and a constant humidity air circulation. In a workshop with a constant environment, the pre-symmetry channel can be downgraded to pre-pressurization detection plus short-stroke temperature regulation, but the initial deviation of the decorative layer still needs to be retained. The determination and this prescription package The handover.

[0043] When in use, step one simultaneously outputs an executable control input, enabling subsequent low-pressure phase locking, differential thermal control, and pin avoidance disengagement to operate continuously around the same plate identifier, reducing the risk of phase drift caused by material batch changes, feeding mismatch, or prescription mismatch.

[0044] Step 2: Before the press is closed at low pressure and the resin enters the melt flow, the phase constraint mechanism completes controlled engagement with the edge alignment reference and outputs a phase-locked status signal that can be called in Step 3.

[0045] The challenge in matching patterns on double-sided insulated composite panels lies not in whether the pattern on one side can be delivered to the mold by the feeding mechanism, but in the fact that after the upper decorative layer, the insulation core material blank, and the lower decorative layer are stacked, the core soft medium will experience thickness compression, edge warping release, and slight slippage of the adhesive layer in the initial closing stage. At this time, the mold relief has not yet been fully pressed into the decorative layer, and the resin has not yet formed a viscous lock. If the pressure is increased too early, the patterns on the upper and lower sides will have slight displacements in different directions on their respective stress surfaces. If alignment is delayed until the resin melts, the decorative layer will have been dragged by the adhesive layer, and mechanical correction will leave tearing at the hole edges or stretching of the pattern. Therefore, step two defines the low-pressure stage as the phase locking window, and uses three types of inputs—pressure, temperature stability, and stroke compensation—to jointly determine the extension time of the pin mechanism, so that the mechanical phase constraint is established before the resin melts.

[0046] After the stacked material pile, which has undergone pre-symmetry in step one, enters the press closing station, the press closing servo performs pre-compensation based on the closing stroke. Correcting the low-voltage landing point; the main control PLC reads the prescription package of this board. The pin extends pressure Window lock duration Duration of temperature difference stability Simultaneously, it receives signals from the press pressure sensor, upper and lower pressure plate temperature sensors, closed servo position encoder, and pin position feedback sensor. Only when three conditions are simultaneously met—pressure entering the pin extension pressure window, residual temperature difference remaining within the inlet band until the temperature difference stabilizes, and closed stroke compensation being confirmed by the servo—does the main control PLC send a pin extension command to the phase constraint mechanism. After the pin extends to its position, the main control PLC does not immediately initiate high-pressure curing; instead, it outputs a phase-locked status signal, a pin position feedback signal, and the remaining time of the locking window to step three, allowing the differential thermodynamic time series to unfold under mechanical constraints.

[0047] The extension action of the phase constraint mechanism is preferably not triggered by a single pressure value, but rather confirmed by the pressure domain, thermal stability domain, and stroke domain. The pressure domain is used to confirm that the decorative layer has been attached to the molded relief but that large-scale resin flow has not yet occurred; the thermal stability domain is used to confirm that the pre-symmetry of step one has not been broken during the pressing process; and the stroke domain is used to confirm the pre-compensation amount of the closed stroke. This is already reflected in the actual closed position.

[0048] For example, when a stack of polyurethane core material enters the press, the pressure plate first closes at a low speed, the edge guide ruler exits the pressing zone, and the pressure sensor reading enters the pin extension pressure. After the corresponding window is opened, the main control PLC continues to observe the residual temperature difference between the upper and lower pressure plates, and waits for the temperature difference to stabilize. Only after the conditions are met is the pin mechanism allowed to extend, thereby avoiding the pin hole misalignment caused by the transient impact when the pressure plate just contacts the material stack.

[0049] The low-pressure locked inlet can be expressed using the following gating mechanism: Among them, the entrance gate control value is locked. The value of is 0 or 1, used to determine the first . Whether the tension plate is allowed to extend the pin; pressure threshold value. The value can be 0 or 1, when the real-time pressure At the lower limit of pin extension pressure With the pin extending the upper limit of pressure Set to 1 if the value is between 1 and 0 otherwise; thermal stability threshold value The value can be 0 or 1, when the residual temperature difference between the upper and lower pressure plates Residues are allowed at the entrance. Duration of time for the internal temperature difference to remain stable Time threshold 1; travel threshold value The value is 0 or 1. When the actual low-pressure landing point returned by the press servo during closure is different from the pre-compensation amount of the closure stroke, the value is 0 or 1. Set to 1 when a match is found; time-gated value The value can be 0 or 1, when the current low-pressure dwell time does not exceed the lock window duration. The threshold value is 1. All the above gate values ​​are determined directly by the main control PLC based on the periodic signal, without relying on offline manual determination.

[0050] In a preferred embodiment, the press pressure sensor is installed near the upper pressure plate hydraulic circuit and the lower pressure plate support circuit. The main control PLC reads the two pressures at the same sampling period and takes the lower reliable value as the real-time pressure. To prevent premature triggering when pressure rises on one side first, the temperature sensors of the upper and lower pressure plates are embedded at the same depth on the back side of the working surface of the mold. The main control PLC does not determine the action based on a single point temperature, but first eliminates measurement points with broken wires, jumps, and obvious lags, and then forms a residual temperature difference between the upper and lower plates. The closed servo position encoder is used to confirm the pre-compensation amount of the closed stroke. If the encoder's feedback position remains at the uncompensated landing point after execution, the pin extension command is retained in the waiting queue.

[0051] During use, the pin extension action is restricted within the window where the resin has not yet flowed and the material stack has already adhered, reducing the impact of the phase restraint mechanism on the decorative layer; simultaneously, the closing stroke pre-compensation amount Including the entry judgment ensures that the correction of core material thickness fluctuation in step one can be truly transmitted to the pin joint landing point in step two.

[0052] The phase constraint mechanism preferably consists of several phase locking pins arranged along the four corners and long edge of the mold. Each phase locking pin includes a pin body, a sealed telescopic cavity, a servo drive unit, and a pin position feedback sensor. The pin body is made of heat-resistant ceramic or heat-resistant alloy, with a D-shaped or T-shaped cross-section. The edge alignment reference includes a mechanical engagement reference and a visual recognition reference. The mechanical engagement reference is a hole, slot, or opening notch that complements the shape of the pin body. It is set within the trimmed redundant strip of the decorative layer and is used to engage with the phase locking pin. The visual recognition reference is a reflection point, a printed mark, or a color difference mark. It is used for edge pre-calibration before the phase locking pin extends and does not penetrate the phase locking pin.

[0053] For example, in the production of standard door panels, a cutting redundancy strip is reserved on the long side of the upper and lower decorative layers. The punching device forms D-shaped holes in the same direction within the redundancy strip and prints a narrow visual recognition reference on the outside of the hole. When the stacked material enters the press, the four corner phase locking pins extend vertically, first passing through the mechanical joint reference of the upper decorative layer, then through the clearance area of ​​the core material edge, and then into the mechanical joint reference of the lower decorative layer. After the pin position feedback sensor returns the position signal, the main control PLC confirms that the upper and lower decorative layers are constrained by the same geometric axis.

[0054] In one embodiment, a set of phase locking pins is set at each of the four corners of the mold, and an auxiliary set of phase locking pins is set at the middle of the long side. The four corner phase locking pins are responsible for establishing the overall coordinates of the plate, and the auxiliary phase locking pins are responsible for suppressing the arc-shaped displacement of the decorative layer on the long side during low-pressure bonding. A rounded corner guide section is set at the front end of the pin body, and after the guide section, it enters the asymmetrical working section. The sealed telescopic cavity is sealed with a bellows or a metal sealing ring to isolate resin volatiles and hot-pressing dust. The servo drive unit can be a heat-resistant stepper motor, a hydraulic micro cylinder, or a pneumatic-hydraulic booster cylinder. Any drive component with the same function can be used, as long as it can complete the feedback linear displacement according to the pin extension command of the main control PLC.

[0055] The extension stroke of the phase locking pin can be pre-compensated according to the closing stroke. Make minor adjustments: Among them, the pin extends the stroke. This indicates the actual displacement of the phase locking pin from the mold retraction position to the engagement position. The pin position feedback sensor performs closed-loop confirmation of the actual displacement, and its value is limited by the allowable stroke of the sealed telescopic cavity; maximum extension stroke. Used to prevent the pin body from being pressed too deeply into the lower decorative layer; minimum extension stroke. Used to ensure that the pin body passes through the upper decorative layer edge alignment reference and enters the lower decorative layer edge alignment reference; basic engagement stroke Determined by the thickness of the molding die, the thickness of the decorative layer, and the clearance depth at the edge of the core material; assembly allowance. Used to compensate for pin head chamfering, slot inlet angle, and adhesive layer thickness; stroke correction factor. Used to adjust the pre-compensation amount of the closed stroke This is a correction amount converted to pin extension stroke, the value of which is obtained from the first piece press-fit calibration. The minimum and maximum values ​​in this expression are used for saturation trimming to adjust the pin extension stroke. It always stays within the safe mechanical travel range.

[0056] To avoid reversed pin hole orientation, the edge alignment reference and pin body preferably use asymmetrical unidirectional matching. One side of the pin body has a straight edge, and the other side has an arc edge or bevel. The slot forms an inlet edge in the same direction. When the decorative layer is misaligned, the pin body cannot smoothly enter the slot, the pin position feedback sensor will not return a position signal, the main control PLC will stop boosting voltage and execute retraction.

[0057] In use, the phase locking pin is not just a positioning pin, but also serves three functions: directional error prevention, coaxial constraint of the upper and lower decorative layers, and transfer of the embossing reference. The asymmetric slots are arranged in the cutting redundancy zone so that mechanical joint marks are removed in the subsequent trimming, reducing interference with the visible finish.

[0058] Around each phase locking pin, a ring-shaped or U-shaped pressure buffer band is preferably provided on the die surface. The pressure buffer band forms a shallow yield relative to the die working surface, so that when the pin extends, the local decorative layer first undergoes controlled yielding, and then the pressure is gradually borne by the surrounding die. This structure is arranged corresponding to the cutting redundancy band where the edge alignment reference is located, and does not participate in the main area of ​​die embossing. The pin extension command is preferably sent via the internal bus of the press. The command fields include the plate identification, pin position number, direction of action, target extension stroke, allowable action time, and verification field. The pin position feedback signal includes the plate identification, pin position number, extension in place mark, retraction in place mark, position deviation, and fault code.

[0059] Upon receiving the pin position feedback signal, the main control PLC first verifies the board identification, and then verifies each pin position number to prevent residual feedback from the previous board from being misused in the current stack. If the feedback field is missing, the main control PLC does not interpret the status as "in place," but instead treats it as a pin engagement anomaly.

[0060] For example, if the decorative layer is impregnated paper, the pressure buffer strip prevents the resin and fibers near the hole edge from being instantly sheared; if the decorative layer is a film, the pressure buffer strip keeps the hole groove guide edge flat, preventing the pin head from being pushed and forming wrinkles.

[0061] After the pins are engaged, the main control PLC calculates the assembly margin based on the extension signal returned by the pin position feedback sensor: Among them, assembly margin This indicates the remaining engagement margin between the phase locking pin and the edge alignment reference; a value greater than 0 allows entry into step three; slot clearance. This indicates the design clearance between the pin body shape and the edge alignment reference; its value is determined by the thickness of the decorative layer and the punching method of the slot; pin machining error. Indicates manufacturing deviation of the pin body shape; reference machining error. Indicates edge alignment reference punching or forming deviation; servo positioning error This indicates the combined positioning deviation of the press closing servo and the pin-driven servo; compensation sensitivity coefficient. Used to characterize the pre-compensation amount of the closed stroke. The influence on the relative height of the pin holes. The above error terms are obtained from equipment calibration, punching inspection, and servo feedback, and do not require re-measuring the pattern inside the press.

[0062] If assembly margin If the value is greater than 0 and all pin position feedback sensors return an extended position signal, the main control PLC generates a phase locked status signal and transmits the pin position status, remaining lock window duration, and current pressure to step three; if any pin position feedback sensor does not return an extended position signal, the main control PLC stops the pressure increase, sends a retraction command to the phase constraint mechanism, marks this board as a pin engagement abnormal board, and guides it to a separate processing path.

[0063] As alternative implementations, the phase constraint mechanism can be replaced by a magnetic adsorption type phase constraint mechanism, a vacuum adsorption type phase constraint mechanism, or an electromagnetic engagement type phase constraint mechanism. The magnetic adsorption type phase constraint mechanism is suitable for scenarios where a soft magnetic marking area is set at the edge of the decorative layer; the vacuum adsorption type phase constraint mechanism is suitable for scenarios where the edge alignment reference is a microporous strip; and the electromagnetic engagement type phase constraint mechanism is suitable for scenarios where a thin-film decorative layer needs to reduce mechanical penetration. All of the above alternatives operate in the low-pressure stage and all use the edge alignment reference as the phase bearing object.

[0064] During use, the pressure buffer band limits the localized stress caused by the pin engagement to within the cut-redundancy band, along with the pin position feedback sensor and assembly margin. Together, they convert the mechanical bonding results into state variables that can be called by the main control PLC; abnormal diversion prevents incomplete bonding stacks from entering the differential thermal time series, reducing the need for subsequent processes to solidify erroneous phases.

[0065] Step 3: Within the alignment locking window where the phase locking pin remains engaged, apply an asymmetric thermo-time sequence to the upper and lower pressure plates that matches the heat transfer and compression characteristics of the core material. This allows the upper and lower resins to simultaneously enter the low viscosity window and outputs a state signal to Step 4 indicating that the pin can be safely switched to avoid disengagement.

[0066] The middle layer of the double-sided insulated composite board is not a rigid substrate, but an insulation core material blank with compressible pores, low thermal conductivity paths, and localized springback. Low-density core materials have more internal pores, making it easier for heat to pass through them and causing asynchronous responses at the upper and lower interfaces. High-density core materials have a higher compressive modulus, allowing for more direct pressure transfer from the pressure plate, but localized heat capacity and interfacial adhesive shear can alter the micro-slip direction of the decorative layer. In step two, the upper and lower decorative layers and the molded relief are locked onto the same geometric datum using phase-locking pins. However, after the resin enters the low-viscosity molten stage, the adhesive layer transitions from a supported state to a flowing state. The alignment of the decorative layer will be affected by the resin flow direction, core material springback, and the temperature difference of the pressure plate.

[0067] Step 3 requires actively changing the heat arrival order of the upper and lower interfaces while phase lock still exists, so that the interfaces that are prone to lag can receive heat or have their holding time compensated in advance, and the interfaces that are prone to softening too early can be pressed into the same viscosity window.

[0068] After receiving the phase-locked status signal, the main control PLC first checks the prescription package of this board. Panel markings and core material categories and target differential temperature Then, the upper and lower pressure plate temperatures, the current press pressure, the remaining time of the locking window, and the pin positioning feedback signal are read. Only when the pin positioning feedback signal remains valid and the current pressure is within the alignment locking window pressure range will the main control PLC switch the independent heating zones of the upper and lower pressure plates to differential thermal control. If the pin positioning feedback is lost, the main control PLC will not continue differential heating, but will maintain the intermediate pressure and request step two to execute abnormal flow diversion. The low viscosity synchronous arrival status signal is used as the basis for determining the pin retraction pressure in step four. This is a prerequisite input for determining whether the shrinkage viscosity window already meets the conditions for relay.

[0069] First, classify the core materials. This is converted to differential temperature polarity and differential temperature amplitude to avoid heating all core materials in the same direction. The main control PLC receives the formula from this board. Read the core material category And from the core material measured density collected in step one Core material compression modulus Thermal conductivity of core material Obtain the heat transfer and compression characteristics of this sheet. Core material thermal conductivity. Preferred from core material category The prescription sheet gives the core material compression modulus. The preferred input is provided by the density level and the first piece compression calibration table; equivalent offline hot plate method measurement, supply batch data, or online infrared identification lookup table can all be used as input sources, but the data should be written into this sheet prescription package. It is now uniformly referred to as the thermal conductivity of the core material. and core material compression modulus . Among them, differential temperature polarity The range of values ​​is Used to determine the target differential temperature Direction; measured density of core material The value range is determined by the material specifications of the insulation core material blank, and is used to characterize the porosity and thermal transfer state of the core material; low density threshold. 35kg / m 3 Up to 40kg / m 3 It is used to determine the low-density area that requires relative heating of the lower pressure plate; High density threshold 40kg / m 3 Up to 45kg / m 3 Used to determine high-density areas requiring relative heating of the upper pressure plate; when the core material's measured density... At low density threshold With high density threshold Between, differential temperature polarity Abrupt changes in pressure plate settings are avoided through linear transition.

[0070] Among them, the target differential temperature The amplitude is not directly given by human experience, but by the heat transfer during core material compression. Interpolation in the prescription table yields: Among them, the core material compresses heat transfer. A dimensionless parameter used to simultaneously characterize compressive force transmission capacity and interfacial thermal response rate; core material compressive modulus. Obtained from core material type, density level, or first-piece compression calibration; core material reference compression modulus. This is the benchmark value in the formulation table for similar core materials; the thermal conductivity of the core material. Obtained from supply batch data, offline hot plate testing, or core material type lookup tables; core material reference thermal conductivity. This is the benchmark value in the prescription table for similar core materials; Target differential temperature The value range is limited by the allowable temperature difference between the upper and lower pressure plates of the press, and is used as the temperature difference setting between the upper and lower pressure plates; prescription difference node. Difference node with prescription Core material category The differential temperature between two adjacent values ​​in the prescription table is used to define the upper and lower bounds of the interpolation; prescription feature nodes With prescription feature nodes The normalized core material compression heat transfer between two adjacent ranges is used to determine the interpolation interval.

[0071] For example, when the low-density foamed core material blank enters the press, the main control PLC reads the differential temperature polarity. If the value is negative, the lower pressure plate is then set to the relatively high-temperature side, allowing heat to compensate for the delayed arrival of the lower interface resin; when the high-density phenolic core board blank enters the press, the differential temperature polarity... When the value turns positive, the upper pressure plate becomes the relatively high-temperature side to offset the resin softening deviation caused by the higher density core material having more direct pressure transmission at the upper interface. The differential direction is triggered by the core material properties, rather than by a fixed empirical curve, so that the core material identification in step one and the mechanical phase locking in step two are combined into the thermal control entry point in step three.

[0072] In differential temperature polarity and target differential temperature Once confirmed, the main control PLC writes the set temperatures to the independent heating zones of the upper and lower pressure plates respectively, and keeps the press pressure at the middle section to maintain pressure.

[0073] The upper and lower pressure plates are preferably divided into four to eight independent heating zones along the length of the plate. Each zone is equipped with an embedded thermocouple or platinum resistance temperature sensor, and temperature regulation is performed by a solid-state relay, a heat transfer oil channel, or an electric heating plate. Steam heating zones or hot oil circulation zones with equivalent functions can also be used, as long as they can receive the set temperatures of the upper and lower pressure plates respectively. The pressure in the middle section is not solely for compaction, but rather to ensure that the upper and lower decorative layers form a continuous contact surface with the insulation core material blank, while preventing large-scale lateral flow of resin before the pin retracts. Among them, the upper pressure plate is set to a certain temperature. The target temperature for the independent heating zone of the upper pressure plate is used to control the heating rate of the resin on the upper decorative layer side; the lower pressure plate is set with a specific temperature. The target temperature for the independent heating zone of the lower pressure plate is used to control the heating rate of the resin on the lower decorative layer side; reference hot pressing temperature. Composed of decorative layer resin system and core material category The prescription table is given; target differential temperature Derived from the aforementioned, it is used to create an asymmetrical setting for the upper and lower pressure plates; the middle section maintains pressure. The target pressure of the press within the positioning locking window is used to maintain interface contact and limit resin crossflow; reference mid-section pressure. Determined by plate thickness and adhesive layer system; temperature difference pressure correction factor Used to determine the target differential temperature The resulting interface softening difference is converted into pressure compensation; stroke pressure correction factor. Used to adjust the pre-compensation amount of the closed stroke The resulting thickness deviation is converted into pressure compensation; closed stroke pre-compensation amount. This is derived from step one and is used to keep the pressure setting consistent with the actual slab thickness.

[0074] After the upper and lower independent heating zones receive the set temperatures, the main control PLC processes the data. Each heating zone uses discrete temperature closed-loop control to generate zone heating control quantities. : Among them, zone heating control quantity Used to drive the Each pressure plate heating zone uses an electric heating plate, a heat transfer oil valve, or a solid-state relay; zone temperature error. The difference between the set temperature and the measured temperature; sampling period. Determined by the main control PLC cycle period; proportional coefficient Integral coefficient and differential coefficients The settings are determined by the pressure plate no-load heating test and the first piece pressing test.

[0075] For example, when an intermittent multi-layer press processes stacks of door panels, after the four corner phase locking pins are all in place, the main control PLC first writes the set temperature of each zone of the upper pressure plate into the upper pressure plate. Then, write the set temperature of each section of the lower pressure plate into the lower pressure plate settings. Then the hydraulic circuit pressure target was switched to the mid-section holding pressure. If the edge of the slab is pre-compensated due to the closed stroke in step one. A larger coefficient leads to earlier establishment of local contact, and the stroke pressure correction factor... It will increase or decrease mid-section holding pressure. This ensures that the pressure buffer zone around the phase locking pin remains in a yieldable state.

[0076] The temperature difference between the upper and lower parts and the pressure are no longer executed separately, but rather form a thermally coupled action around the same plate marking; when the resin begins to soften, the decorative layer is already restricted by the pin mechanism, and the phase will not shift due to the flow on one side first.

[0077] During the differential thermo-time series operation, the main control PLC continuously reads the upper platen temperature, lower platen temperature, current press pressure, and remaining lock window time, and estimates the viscosity based on the resin system formulation. This estimation is not a mathematical calculation detached from the equipment, but rather incorporates temperature sensor data and press timing information into the same resin state determination. The basic resin parameters are derived from the incoming material formula of the decorative layer film or impregnated paper, or can be established through offline rheological testing of the same batch. These parameters are then written into the production line formula table and retrieved by the main control PLC. (Viscosity estimate) This is only used to determine the handover time in step four and is not used as data for claiming finished product performance. The resin represents the temperature. With the amount of reaction process Obtain it as follows: Among them, resin represents temperature. Used to indicate the common thermal state of the upper and lower interface decorative resin adhesive layers; upper interface weight. Weight of the lower interface The values ​​range from 0 to 1, and their sum is 1. This is determined by the thickness of the decorative layer, the amount of adhesive applied, and the contact state of the pressure plate; the upper interface thermal hysteresis time... Thermal hysteresis time at the lower interface The temperature was obtained from the initial thermocouple embedding test or a similar material formulation table; the actual temperature of the upper pressure plate was measured. Measured temperature of the lower pressure plate These are the temperatures after deducting interfacial thermal hysteresis. Among them, reaction process quantity The value range is 0 to 1, used to indicate the degree to which the decorative layer resin adhesive layer develops from flowing to viscous adhesion; the reaction initiation time. This refers to the moment when step three enters differential thermodynamic control; the reaction rate coefficient. and reaction activation parameters Obtained from resin supply formulation or offline rheological testing; gas constant For calculation constants; integration variables This indicates the time elapsed from the start of the reaction to the current moment. Among them, viscosity estimate Indicates the first Zhang Ban at the moment The resin flow resistance is used to determine whether the low viscosity window has been entered; initial viscosity. Derived from the resin formulation of the decorative layer, used to indicate the resin state before injection; temperature sensitivity coefficient. This is a parameter describing the softening effect of resin upon heating, used to describe the contribution of temperature increase to viscosity decrease; the resin represents the temperature. The reference temperature is obtained by weighting the upper platen temperature, lower platen temperature, and interface hysteresis time, and is used to characterize the common thermal state of the upper and lower interfaces; Reference temperature in the resin formulation; curing growth factor The parameters for viscosity recovery after the resin begins crosslinking; reaction progress rate. This has been obtained from the aforementioned recursive formula and is used to indicate the degree to which the decorative layer resin adhesive layer changes from flowing to viscous locking.

[0078] When viscosity estimate When the low viscosity synchronization window is entered, and both the upper and lower pressure plate temperatures are within their respective set temperature allowable ranges, while the pin position feedback signal remains valid, the main control PLC generates a low viscosity synchronization arrival status signal; this signal, along with the current pressure and the current resin representative temperature, indicates that the low viscosity synchronization has been achieved. Remaining time of the locked window and the prescription package on this board. Proceed to step four.

[0079] For example, when this method is used in a continuous double steel belt press, the phase constraint mechanism can be replaced by an edge vacuum adsorption belt instead of a phase locking pin, and the heating zones of the upper and lower steel belts are set at the same target differential temperature. Set viscosity estimate After the handover conditions are met, the vacuum adsorption belt is released and the pressure-increasing curing section is entered. For production lines without independent temperature zones, upper and lower pressure holding time difference or upper and lower pressure difference can be used as parallel implementation methods. The judgment principle is still to align the upper and lower resin viscosity-time curves and form a viscous locking state before the mechanical phase constraint is released, so that on-site operators can directly understand the handover conditions from the three types of signals: pressure plate, pressure and pin position.

[0080] When in use, the output of step three is not an abstract temperature control result, but a handover signal that can be directly used in step four; mechanical constraints, differential heating and resin viscosity determination are closed within the same window, reducing the risk of phase drift and hole edge damage caused by premature or late pin retraction.

[0081] Step 4: Based on the low viscosity synchronous state of the resin formed in Step 3, control the phase constraint mechanism to complete the avoidance and separation before pressure curing, and through pressure curing and alignment result feedback, make the upper and lower pattern phases of the double-sided thermal insulation composite board smoothly switch from mechanical locking to resin viscous locking.

[0082] In step two, the phase locking pins have constrained the upper decorative layer edge alignment reference, the lower decorative layer edge alignment reference, and the embossing reference to the same geometric coordinates; in step three, the upper and lower pressure plates are then connected via the target differential temperature... and maintain pressure in the middle section This brings the upper and lower resins to the same low viscosity window. If the phase-locking pin remains in the groove and high pressure is applied directly, the pin itself will be subjected to high-pressure shearing, and the sealed expansion cavity will be squeezed by resin volatiles and cured products. If the pin retracts prematurely before it develops viscous bonding capacity, the phase constraint established in step two will suddenly disappear, and the decorative layer will experience slight slippage due to the flow of the adhesive layer and the rebound of the core material. Especially in scenarios where there is a clearance area at the edge of the insulation core material and the redundant trimmed strip of the decorative layer has not yet been removed, the area around the groove is both a mechanical bonding area and a subsequent stress release area. Too rapid a retraction will drag fibers or film, while too slow a retraction will solidify the pin mark between the edge layers. Therefore, step four uses the pin retraction pressure... Retraction viscosity window, resin representative temperature Using the feedback signal of the pin position as a common entry point, the timing of mechanical constraint withdrawal is defined, and the pressure rise, pressure holding and solidification, cooling and pressure release and edge visual detection after withdrawal are linked into an executable process chain.

[0083] After receiving the low-viscosity synchronization arrival status signal, the main control PLC does not immediately retract the phase locking pin, but first checks the board markings and core material type. Closed-loop pre-compensation amount The system checks the remaining time of the locking window and the feedback signal indicating that all pins are in position. Subsequently, the main control PLC enters the pin retraction gate control judgment, continuously reading the current press pressure and resin representative temperature. Viscosity estimate , reaction process quantity Displacement feedback from the pin drive unit. When the pressure is at the pin retraction pressure... In the corresponding window, the resin represents the temperature. Located within the avoidance temperature zone specified in the resin formulation, the estimated viscosity value Located at the lower limit of shrinkage viscosity With upper limit of shrinkage viscosity Between, and the amount of reaction process Once the board has entered the tacky bearing zone, the main control PLC sends a retraction command to the phase constraint mechanism. After retraction, the press enters the pressure-boosting curing phase with a safety delay. After curing, the edge vision inspection station reads the alignment result and generates a prescription table for correction suggestions. If any pin feedback signal is lost, the board markings are inconsistent, or the retraction action exceeds the allowable retraction time, the main control PLC maintains or reduces the pressure and stops the pressure ramp, keeping the abnormal board in a low-risk, manageable state.

[0084] Among them, pressure is used to confirm that the material stack has transitioned from the pressure maintained in the middle section to the pressure-bearing state before the pressure increase; temperature is used to confirm that the upper and lower resins are in the common reaction zone after the differential thermodynamic time series; viscosity is used to determine whether the resin has the flow damping to replace the pin constraint; and pin position feedback is used to eliminate misjudgments caused by individual phase locking pins not maintaining extension.

[0085] For example, in a multi-layer intermittent press, when a stack of phenolic core material undergoing formulation processing enters this step, the main control PLC first maintains the intermediate holding pressure. Waiting for the resin to reach the indicated temperature Enter the avoidance temperature zone; the pin retraction threshold is only allowed when the feedback from the four corner pins still indicates that they are extended to the correct position. The process changes from closed to open. For polyurethane or polystyrene core materials, the resin flow duration after heating differs; the main control PLC still uses the same gating structure, only the formulation package for this board needs to be replaced. Sales contraction pressure It shrinks the viscosity window and avoids the temperature band without changing the equipment action chain.

[0086] In the preferred implementation, the lower and upper limits of pin retraction pressure are determined by the pressure curve during the first test press. The avoided temperature zone is determined by the resin supply formula and the actual temperature rise lag of the press plate. The reaction process is obtained by recursively calculating the heating time, holding time, and resin representative temperature in step three. All the above parameters are bound to the plate identification in the current plate formula package, and temporary readings are not borrowed across plates, thereby avoiding the thermal inertia of the previous plate being incorrectly carried over to the current plate. When the press is a double steel belt continuous press, the plate identification can be generated by the conveying position code and the pressing time, and the gate control is triggered sequentially along the direction of plate movement. Among them, the pin retraction gate value The value of is 0 or 1, used to determine the first . Whether the tension plate is allowed to perform pin retraction action; pressure retraction threshold value. The value can be 0 or 1, when the current pressure of the press is at the lower limit of the pin retraction pressure. Upper limit of sales pullback pressure Take 1 when in between; temperature pullback threshold value The value can be 0 or 1, when the resin represents the temperature. Located at the lower limit of the avoidance temperature Avoiding the upper limit of temperature Take 1 when between; viscosity shrinkage gate value The value can be 0 or 1, when the viscosity estimate is... Located at the lower limit of shrinkage viscosity With upper limit of shrinkage viscosity Between and the reaction process amount Take 1 when the adhesive bearing range is within the range; pin retains the threshold value. The value is 0 or 1. It is 1 when all phase locking pins return the extended position signal and the board markings are consistent.

[0087] The aforementioned gate values ​​are all determined by the main control PLC according to the same sampling period. When any gate value is 0, the current pressure is maintained and pressure increase for curing is prohibited. The pin retraction action is limited to a window within which the resin can accept the phase, but the pin body is not yet locked by the cured resin. At the same time, pressure, temperature, viscosity, and pin position signals are cross-checked to reduce the risk of false triggering caused by fluctuations in a single sensor and to allow for different core material types to retract. The retraction logic maintains the same execution approach.

[0088] When the pin retraction gate value When the value is 1, the main control PLC sends a pin retraction command to the phase constraint mechanism. The command fields preferably include the plate identifier, pin position number, target retraction stroke, allowable retraction time, retraction speed level, and check code. The phase locking pin retracts along the sealed telescopic cavity into the mold. After the front end of the pin body leaves the alignment reference of the upper decorative layer edge, the clearance area of ​​the core material edge, and the alignment reference of the lower decorative layer edge, the pin position feedback sensor returns a retraction completion signal. The main control PLC checks the pin position number one by one, and starts the pressure ramping up only after all pins have retracted to the completion.

[0089] In the preferred embodiment, the pin body is made of heat-resistant ceramic or heat-resistant alloy, the sealing telescopic cavity is sealed with a metal sealing ring or bellows, and an exhaust micro-groove is provided in the mold to release the resin volatiles near the pin cavity; a hydraulic micro-cylinder, a pneumatic-hydraulic booster cylinder or a heat-resistant stepper motor with equivalent function can all be used as the drive unit.

[0090] For example, if the decorative layer is impregnated paper, the pressure plate maintains a short-term constant pressure at the moment of pin retraction, preventing the fibers around the slot from being dragged by the pin head; if the decorative layer is thermoplastic film, the press can perform a reverse light pressure stroke at the moment of retraction. The reverse light pressure stroke only releases the partial contact of the slot and does not change the overall closed thickness of the plate. If the phase constraint mechanism uses a vacuum adsorption belt or magnetic adsorption ring, the main control PLC replaces the retraction command with an action command to release the negative pressure or disconnect the excitation, and still uses the plate identification, action duration, and feedback status as the verification objects. This ensures that the mechanical pin scheme and the non-penetrating scheme share the same avoidance window and the same boost relay logic in step four, and field maintenance personnel can also judge the completion of the action by the same status lights. Among them, the time of pressure boosting start Indicates the first The moment when the sheet begins to pressurize and solidify; the moment when the pin begins to retract. Indicates the moment when the main control PLC issues a valid pin retraction command; safety delay. This indicates the waiting time between the start of pin retraction and the start of pressure boost, preferably 10ms to 30ms; maximum safety delay. and minimum safe delay These are used to prevent voltage boosting too late or too early; base delay. The calibration response originates from the pin drive unit; travel delay factor. Used for extending the pin's travel. Convert to pullback with waiting compensation; pullback viscosity window value From the lower limit of shrinkage viscosity With upper limit of shrinkage viscosity Calculated viscosity delay coefficient Used to convert viscosity estimates With the midpoint of the shrinkage viscosity window The difference is converted into waiting compensation. The above maximum and minimum value selection constitute the saturation pruning rule, ensuring a safe delay. Maintain within the executable window. After retraction, the press pressure is increased to the boost curing pressure, preferably more than 85% of the rated pressure; the temperature of the upper and lower pressure plates is maintained within the curing temperature range specified in the resin formulation, preferably 160°C to 200°C. The holding time during the boost curing stage can be adjusted according to the curing time. Sure: Among them, curing time Used to control the holding time during the pressure boosting and curing stage; curing time coefficient By core material category and resin system The prescription is given in units of time per thickness; target thickness of the sheet material. From production plan or thickness measuring device; reference compensation time It is used to compensate for the thermal inertia of the pressure plate and the hysteresis of the initial reaction of the resin.

[0091] There is a measurable relay interval between the phase locking pin's withdrawal and the pressure-curing process. After the mechanical constraint is released, the position of the decorative layer is immediately taken over by the resin adhesion and high-pressure curing, avoiding periods of unconstrained drift. At the same time, the sealed telescopic cavity and the exhaust micro-groove enable the pin mechanism to have repeatable operation conditions in the high-temperature resin environment.

[0092] After the pressure-boosting and curing stage, the press enters the cooling and pressure-releasing phase. The main control PLC then adjusts the pressure according to the board thickness and core material type. The resin formulation controls the cooling water or air cooling channels to ensure the sheet material completes a transportable state transition before leaving the press. After leaving the press, the sheet material enters the edge vision inspection station. The inspection targets are preferably the decorative layer pattern feature points, embossed reference points, and residual positions of edge alignment references within the cutting redundancy zone. An industrial camera, coaxial light source, and fixed-distance conveyor rollers together form a fixed field of view. The main control PLC or production line main control performs noise reduction, binarization, feature point positioning, and pixel distance calculation on the image, outputting the maximum offset, four-corner offset, and inspection pass mark. Alignment error. The directional composite error is formed by the alignment error of the detection positions of the left front corner, right front corner, left rear corner, and right rear corner. The offset direction is based on the offset of the decorative layer pattern feature points relative to the stamping relief reference point along the feeding direction.

[0093] For example, after the standard door panel is sent out from the press outlet, the conveyor roller first makes the long side of the panel fit against the reference side. The edge visual inspection station then takes pictures of the left front corner, right front corner, left rear corner and right rear corner in sequence. The production line main controller writes the offset fields of the four positions into the process data log of this panel and feeds back the offset direction to the prescription table for recursive correction.

[0094] If the detected image is obscured by dust, the production line controller retains the process data log for this board but does not generate a prescription table for correction suggestions, in order to avoid abnormal images causing unreasonable influence on the prescription of subsequent boards. Among them, the detection position alignment error For the first Signed error at each detection location; pixel equivalent and The x-coordinates of the feature points in the decorative layer were obtained by conversion from the calibration plate within the camera's field of view. ordinate of decorative layer feature points The position of the grayscale peak value is obtained from the centroid method or bilinear interpolation; the x-coordinate of the embossed reference point. Vertical coordinates of the embossed relief reference point Obtained by matching the mold reference mark or standard plate template; set of detection positions Including the front left corner, front right corner, rear left corner, and rear right corner; maximum alignment offset. Used to determine the first Does the prescription plate exceed the allowed offset threshold in the prescription form? Among them, the recommended differential temperature This indicates a suggested revision to the prescription sheet for the next similar core material sheet, without directly altering the completed sheet; target differential temperature. Derived from step three, used as the baseline for this correction; correction learning rate The value range is 0 to 1, used to control the correction range of the prescription form; trimming mean error. From near plate set The signed alignment error was calculated in the near-plate set. These are several sheets of the same core material, the same decorative layer, and produced under the same press operating conditions; alignment error The error trimming threshold is generated by the edge vision inspection station based on the offset direction between the decorative layer pattern feature points and the embossed reference points; Used to limit the impact of abnormal images or abnormal panels on the prescription form; Saturation clipping function The specific form has been given in the formula, and those skilled in the art can directly implement it by calculating the minimum and maximum values. As a parallel implementation method, the edge vision inspection station can be replaced by an offline sampling inspection station, and the prescription table recursive correction can be executed by the local main control of the production line, or the process server can generate correction suggestions after receiving the board identification and process data log; the phase constraint mechanism can also be avoided by sliding laterally along the board plane, removing the detachable pin head, releasing the vacuum adsorption belt, or demagnetizing the magnetic adsorption ring.

[0095] The alignment results after the finished product is pressed are returned to the original prescription package. The data link it belongs to, the target differential temperature of the next board. The timing of the pinning and sewing actions can be finely adjusted accordingly; at the same time, the visual inspection position is located within the cutting redundancy zone, which does not change the visible finish of the finished product, and provides parallel support under the same technical principle for online inspection and offline sampling inspection in subsequent claims.

[0096] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0097] Those skilled in the art will understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0098] In the several embodiments provided in this application, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0099] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0100] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A method for synchronous hot pressing of double-sided thermal insulation composite panels, wherein the press is controlled by a press control system, characterized in that, include: Obtain the core material condition data and edge alignment reference information of the upper and lower decorative layers of the same stacked material. The core material condition data includes the core material type and core material thickness. The stacked material is controlled to enter the press, and the phase constraint mechanism is driven to apply phase constraint to the edge alignment reference during the low-pressure closing stage when the resin is not melted, so that the upper decorative layer, the lower decorative layer and the molded relief form a phase-locked state. During the phase-locked state, the upper and lower pressure plates are controlled to perform asymmetric thermo-differential timing based on the core material state data, and a low viscosity window state signal is generated when the upper and lower resins reach the preset low viscosity window. Based on the low viscosity window state signal, pressure state, temperature state, and viscosity state, the phase constraint mechanism is driven to disengage from the edge alignment reference before pressurization and curing, and the press is controlled to pressurize and cure.

2. The synchronous hot pressing molding method according to claim 1, characterized in that: After acquiring the core material status data, the press control system generates a plate identifier for the stacked material stack and writes the core material thickness, core material type, edge alignment reference information and the low-pressure landing point of the press closing servo into the sheet prescription package. The press control system generates a pre-compensation amount for the closed stroke based on the core material thickness, and transmits the pre-compensation amount for the closed stroke to the low-pressure closing stage along with the board marking. When the pre-compensation amount for the closed stroke falls into the allowable window of the press closing servo, the low-pressure closing is executed. When it does not fall into the allowable window, the phase constraint action is stopped and the degraded board mark is output.

3. The synchronous hot pressing molding method according to claim 2, characterized in that: During the low-pressure closing phase, the press control system reads the phase constraint mechanism action pressure window, inlet temperature difference residual window, and locking window duration in this sheet prescription package, and reads the actual low-pressure landing point of the press closing servo. When the pressure, temperature, stroke, and timing states all enter the corresponding window, an extension command is sent to the phase constraint mechanism; when any state does not enter the corresponding window, low pressure is maintained and pressure increase for curing is prohibited.

4. The synchronous hot pressing molding method according to claim 3, characterized in that: The phase constraint mechanism includes at least one phase locking pin, and the edge alignment reference includes a mechanical engagement slot disposed within the trimming redundancy band; the phase locking pin has an asymmetrical cross section, and the mechanical engagement slot has a unidirectional guide edge corresponding to the asymmetrical cross section; the edge region of the embossed relief is provided with a pressure buffer band surrounding the phase locking pin; When the phase lock pin sends back a signal indicating it is in position, it is allowed to enter the asymmetric thermal differential timing sequence. When it does not send back a signal indicating it is in position, the phase lock pin retracts and an engagement failure flag is output.

5. The synchronous hot pressing molding method according to claim 4, characterized in that: The phase constraint mechanism is a vacuum adsorption type phase constraint mechanism. The edge alignment reference includes a microporous strip set along the edges of the upper and lower decorative layers. The press control system opens the vacuum channel at the edge of the pressing template during the low-pressure closing stage, so that the microporous strip is attached to the edge reference surface of the pressing mold relief. When the vacuum negative pressure reaches the adsorption window, the phase lock state is maintained. When the vacuum negative pressure does not reach the adsorption window, the pressure increase is stopped and an adsorption abnormality mark is output.

6. The synchronous hot pressing molding method according to claim 5, characterized in that: When the press control system executes the asymmetric thermo-differential timing sequence, it reads the heating zone configuration of the upper and lower pressure plates. When both the upper and lower pressure plates have independent heating zones, the set temperatures for the upper and lower pressure plates are written respectively; when at least one pressure plate is not configured with an independent heating zone, the same reference hot pressing temperature is maintained, and differential control is applied to the contact holding time of the upper and lower pressure plates.

7. The synchronous hot pressing molding method according to claim 6, characterized in that: The press control system reads the actual temperature, pressure, and viscosity of the upper and lower pressure plates during the phase-locked state. When a low viscosity window state signal is generated within the predetermined holding period of the phase-locked state, disengagement is performed according to the pressure, temperature, and viscosity states. When the low viscosity window state signal is not generated within the predetermined holding period, the phase constraint mechanism is maintained and the process enters the degraded pressure boosting curing path, while the board identification is written to the abnormal process log.

8. The synchronous hot pressing molding method according to claim 7, characterized in that: The action command message sent by the press control system to the phase constraint mechanism includes the plate identifier, process stage identifier, phase constraint mechanism number, action direction, target stroke, action pressure window, allowable action time, and verification field. The feedback message returned by the phase constraint mechanism includes the plate identifier, phase constraint mechanism number, positioning mark, position deviation, and fault code. When the plate identifiers of the two messages are consistent, the feedback message is adopted; when they are inconsistent, the feedback message is discarded and the current pressure state is maintained.

9. The synchronous hot pressing molding method according to claim 8, characterized in that: After sending the action command message, the press control system generates a differential control setting message, which includes plate identifier, upper platen setting value, lower platen setting value, differential mode field, phase lock status flag, low viscosity window status signal, and effective cycle time field. When the phase lock status flag is valid, the differential control setting message is written to the pressure plate controller; when the phase lock status flag is invalid, the differential control setting message is not written and the current pressure status is maintained.

10. The synchronous hot pressing molding method according to claim 9, characterized in that: After the press curing is completed, the press control system outputs process data logs and human-machine interface status; the process data logs include board identification, low-pressure lockout stage timestamp, differential control setting message, action command message, feedback message, press curing start time, and abnormal flags; The human-machine interface displays the status in sequence as standby, low-pressure lock, differential heating, mechanism disengagement, pressure boosting and curing, and abnormal diagnosis. When the abnormal marker is empty, the pressure boosting and curing completion status is displayed; when the abnormal marker is not empty, the abnormal diagnosis status is displayed.

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