Door Panel Foam Injection Press Design
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Solution Overview
Problem
Existing methods for manufacturing insulated door panels face challenges such as suboptimal connection between insulating materials and peripheral frames, leading to reduced rigidity, significant waste generation, and difficulties in achieving homogeneous filling, especially with the presence of ocular elements, along with potential deformation issues due to high pressure requirements for foam injection.
Innovation Solution
A method involving a press-type installation with a horizontal press support and press cover, where a liquid or semi-liquid insulating foam mixture is deposited into the central housing and allowed to expand, ensuring homogeneous filling and minimizing frame deformation, with optional venting and wedging to manage pressure and prevent adhesion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pre-cut plate of insulating material is positioned within the central housing and facings are fixed on both sides, then the insulating structure is installed, but the bonding between insulating material and peripheral frame is suboptimal, limiting rigidity
Solution Approach 1:
The patent changes the state of insulating material from pre-cut solid plate to liquid or semi-liquid expanding foam mixture. This parameter change allows the material to flow into all cavities and bond optimally with the peripheral frame and facings, resolving the bonding quality issue while maintaining rigidity.
Solution Approach 2:
The patent utilizes phase transition of insulating material from liquid/semi-liquid state to expanded solid foam state. The material is injected in liquid form, expands within the cavity, and solidifies to form a rigid bonded structure, simultaneously achieving excellent bonding and rigidity.
2Quantity of substance
If a liquid or semi-liquid mixture of expanding insulating foam material is injected under pressure into the central housing, then filling is achieved, but relatively high pressures are required which are difficult to implement and control, and may cause residual deformations of the peripheral frame
Solution Approach 1:
The patent applies preliminary action by positioning wedges between the peripheral frame and press support before foam injection. These wedges pre-establish a mechanical constraint system that will control and limit the pressure exerted on the frame during foam expansion, preventing deformations while allowing complete filling.
Solution Approach 2:
The wedges act as intermediary elements between the expanding foam and the peripheral frame. They mediate the pressure transmission, allowing the foam to expand and fill the cavity while distributing and limiting the pressure to prevent frame deformation.
3Quantity of substance
If foaming material is injected through an injection orifice in the peripheral frame, then the central cavity can be filled, but homogeneous filling is not guaranteed, particularly when an oculus is present
Solution Approach 1:
The patent segments the injection system by providing multiple injection orifices distributed across the press support surface. This segmentation allows the foam to be injected from multiple locations simultaneously, ensuring homogeneous filling of the entire central cavity including areas around ocular elements.
Solution Approach 2:
The patent transitions from a single-point injection (vertical dimension only) to a distributed multi-point injection system (adding horizontal dimension). Multiple orifices arranged in rows and columns create a two-dimensional injection pattern, ensuring uniform foam distribution throughout the cavity.
4Reliability
If insulating expanded foam adheres to the inner faces of the cladding, then bonding is achieved, but problems of deformation of the opening panel occur in the event of aluminum sheet cladding expansion under heat
Solution Approach 1:
The patent modifies the injection parameters by controlling foam expansion rate and using multiple small orifices instead of single large injection. This creates a gentler, more distributed expansion process that reduces localized stress on aluminum cladding, preventing deformation while maintaining adhesion.
Solution Approach 2:
The patent applies preliminary protective action by positioning the peripheral frame and wedges before foam injection. This pre-established constraint system controls the expansion pressure distribution, preventing excessive localized pressure on aluminum cladding that could cause deformation during thermal expansion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves a rigid and resistant assembly with reduced material waste, ensuring complete and uniform filling of the panel, maintaining frame integrity, and allowing for flexible facing material choices while minimizing deformation and adhesion problems.
Implementation Method 1
deposit a liquid or semi-liquid mixture of expanding insulating foam material into said central housing
Implementation Method 2
a liquid or semi-liquid mixture of expanding insulating foam material, for example a mixture of polyol and isocyanate which, after polymerization, forms an insulating polyurethane foam
Implementation Method 3
actuate said press cover to rest it on said peripheral frame and close said top housing opening
Implementation Method 4
positioning, in the central housing, a plurality of wedge-shaped elements distributed over the entire surface of the peripheral frame, said wedge-shaped elements being adapted to distribute and limit the pressure exerted by the expanding insulating foam on the peripheral frame
Implementation Method 5
which at least one vent is adapted to allow the evacuation of pressurized air inside the central housing of said peripheral frame during the expansion of the liquid or semi-liquid mixture of insulating expandable foaming material
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The present invention relates to a method for manufacturing a door opening panel comprising: - a peripheral frame delimiting a central housing, - an insulating structure placed within said central housing, - an inner facing, and - an outer facing. The method comprises the following operations: (a) preparing said peripheral frame, (b) providing a press-type installation comprising a horizontal press support and a press cover, (c) placing said peripheral frame on said horizontal press support, (d) depositing a liquid or semi-liquid mixture of expanding insulating foam material into said central housing through the upper opening of the housing, (e) actuating the press cover to bring it into contact with said peripheral frame and close said upper opening of the housing, (f) allowing the expanding insulating foam material to expand within the central housing.(g) after full expansion of the insulating expanding foam material, to actuate the press cover to separate it from said peripheral frame, and (h) to extract the peripheral frame/insulating foam assembly from said press.