GRP door manufacturing system

A glass fiber reinforced plastic (GRP) door manufacturing system configured to manufacture a GRP door composed of a wood frame, a first GRP door skin and a second GRP door skin covered on each of an upper surface and a lower surface of the wood frame, and a flame retardant urethane foam filled in a space within the wood frame, wherein the GRP door manufacturing system comprises:

• a GRP door skin stacking stand, wherein GRP door skins including the first GRP door skin and the second GRP door skin are stacked on the GRP door skin stacking stand in multiple layers;
• a wood frame stacking stand, wherein the wood frame is stacked on the wood frame stacking stand in multiple layers;
• a first conveyor configured to transfer the GRP door skins supplied from the GRP door skin stacking stand along a conveyance path;
• a plasma processing unit comprising plasma processors, the plasma processors being respectively located at an upper surface and a lower surface of the first conveyor, being configured to be moved perpendicular to the conveyance path by power of a driving source, and configured to respectively plasma-process an inner surface and an outer surface of the GRP door skins moving along the conveyance path on the first conveyor;
• a second conveyor located downstream from the plasma processing unit and configured to transfer the GRP door skin after plasma processing;
• a bonding unit located above the second conveyor and comprising an application roller configured to apply an adhesive on the inner surface of the GRP door skins moving on the second conveyor;
• a third conveyor configured to transfer the GRP door skins after adhesive is applied;
• a preheating unit surrounding the third conveyor and configured to preheat the GRP door skins moving on the third conveyor;
• a GRP door skin and wood frame inserting unit comprising:
• a robot arm, a plate, a wood frame clamping part, and a GRP door skin absorber;
• wherein the robot arm is located downstream from the preheating unit and configured to be operated according to a control signal preset in a control unit;
• the plate is provided on the robot arm;
• the wood frame clamping part is provided on an outer portion of the plate and configured to clamp and take out the wood frame stacked on the wood frame stacking stand;
• and
• the GRP door skin absorber is provided on an outer surface of the plate, wherein while the wood frame clamping part clamps the wood frame, the GRP door skin absorber absorbs and takes out the first GRP door skin after the first GRP door skin has passed through the preheating unit;
• a GRP door skin reverse unit located at above the third conveyor downstream from the preheating unit, wherein the GRP door skin reverse unit is configured to absorb and reverse the second GRP door skin to a reverse position after the second GRP door skin has passed through the preheating unit, wherein in the reverse position the inner surface of the second GRP door skin is directed downwards after previously facing upwards;
• a forming unit comprising a forming mold including a lower mold and an upper mold;
• the lower mold comprising a core, wherein the wood frame and the first GRP door skin are supplied onto the core by the GRP door skin and wood frame inserting unit;
• a flame retardant urethane foam inlet configured to fill the flame retardant urethane foam into the space within the wood frame after the wood frame is received with the first GRP door skin onto the core of the lower mold;
• wherein the GRP door skin and wood inserting unit is configured to retrieve the second GRP door skin supported in the reverse position on the GRP door skin reverse unit and to supply the second GRP door skin onto the wood frame and first GRP door skin received onto the core of the lower mold;
• and
• wherein the forming mold is configured to form the GRP door by thermocompressing the second GRP door skin, the wood frame, and the first GRP door skin between the lower mold and the upper mold.