GB2301791A - Moulding an aseptic seamless door - Google Patents
Moulding an aseptic seamless door Download PDFInfo
- Publication number
- GB2301791A GB2301791A GB9611709A GB9611709A GB2301791A GB 2301791 A GB2301791 A GB 2301791A GB 9611709 A GB9611709 A GB 9611709A GB 9611709 A GB9611709 A GB 9611709A GB 2301791 A GB2301791 A GB 2301791A
- Authority
- GB
- United Kingdom
- Prior art keywords
- layer
- mould
- glass fibre
- polyester
- laying
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
- B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
-
- E—FIXED CONSTRUCTIONS
- E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
- E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
- E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
- E06B3/70—Door leaves
- E06B3/80—Door leaves flexible
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/724—Doors
Abstract
A method for the manufacture of an aseptic, seamless swing door comprising a number of steps including - providing identical first and second moulds 50,70; coating the surface of each mould with a gel coat; applying a plurality of layers of polyester and glass fibre 61-67, the distribution of the layers in the mould varying from layer to layer; providing a filler core member 68 in one of the moulds; closing the mould by placing one mould on top of the other in mirror-image relationship and subjecting the combination mould to a pressure of 68.9-206.8 kPa before removal of the formed door from the mould and finishing.
Description
A METHOD OF MANUFACTURE OF A SWING DOOR
This invention relates to a method for the manufacture of a door. In particular, it relates to a method of manufacture of an aseptic semi-flexible seamless swing door.
Seamless doors are required in environments where a very high standard of hygiene is required to the extent that the door should not have any cavity or crevice therein.
The invention, therefore, provides a method for the manufacture of a door which method comprises the steps of: (a) providing a first mould and second mould which
are identical to each other, each mould, having
in cross-section a relatively long length of
substantially constant cross-section leading to
a downwardly sloping part which terminates in a
well the opposite side of which comprises a
substantially vertical wall leading to a
relatively short length of substantially
constant cross-section and having the same
thickness as that of the relatively long length; (b) coating the surface of each mould and associated
wall with a layer of isophthalic gel coat and
allowing it to cure until tacky; (c) coating the surface of each mould with a first
layer of a polyester; (d) laying a respective first layer of glass fibre
along the relatively short length;; (e) coating the first layer of glass fibre with a
second layer of a polyester; (f) laying a respective second layer of glass fibre
along the first layer of glass fibre which
second layer has a length sufficient to cover
the vertical wall; (g) laying a respective third layer of glass fibre
along the relatively long length which layer has
a length sufficient to cover the sloping part
and the well; (h) coating the third layer of glass fibre with a
third layer of a polyester; (i) laying a respective fourth layer of glass fibre
on top of the third layer so as to substantially
cover it; (j) coating the fourth layer of glass fibre with a
fourth layer of a polyester; (k) laying a respective fifth layer of glass fibre
over the second layer but excluding the vertical
wall; (1) coating the fifth layer of glass fibre with a
fifth layer of a polyester;; (m) laying a respective sixth layer of glass fibre
over the fifth layer said sixth layer having a
length sufficient to cover the well and extend a
distance along the relatively long length; (n) laying a respective seventh layer of fibreglass
over the fourth layer or substantially the
length of the fourth layer so to overlap the
sixth layer; (o) in the case of the first mould, providing a
filler core layer having substantially the shape
and configuration of the well and the side walls
thereof; (p) placing the second mould on top of the first
moulds in mirror image relationship to form a
combination mound; (q) placing the combination mould in a press at
between 68.9kPa-206.8kPa (10-30psi); (r) removing the combination mould from the press
and removing the thus formed door therefrom; and (s) finishing the door.
Preferably, the combination mould is subject to a pressure in step (q) for a period of between 70 and 80 minutes, preferably 75 minutes.
Preferably, the combination mould is subject to a pressure in step (q) at a temperature of between 170C and 22"C, preferably 200C.
Preferably, the polyester layer comprises a pre-accelerated non-saturated amino polyester resin with a built-in inhibitor together with an organic peroxide which serves to provide a gel and subsequently cure the polyester resin.
Preferably, the thickness of each of the first-fifth glass fibre layers is approximately 0.45mm and the thickness of each of the sixth-seventh glass fibre layers is approximately 0.9mm.
The invention will be understood in greater detail from the following description of a preferred embodiment thereof given by way of example only in which:
Figure 1 is a cross-sectional diagrammatic view
of a mould and a door showing the stages of
manufacture;
Figure 2 is a plan view of a door produced by
the method according to the invention; and
Figure 3 is a perspective view of the door of
Figure 2 of the drawings.
Referring now to the drawing, there is shown a first mould 50 and a second identical mould 70. As each of the moulds 50, 70 are identical, only one of them need be described. Thus, the first mould 50 comprises, in cross-sectional view, a relatively long length 51 of substantially constant cross-section leading to a downwardly sloping wall 52 which terminates in a well 53 having a base 54 which leads into a substantially vertical wall 55 leading to a relatively short length 56 of substantially cross-section and having the same thickness as that of the relatively long length 51.
The following steps described with respect to the first mould 50 are equally applicable to that of the second mould 70.
Thus, the mould 50 is coated with a layer 57 of an isophthalic gel coat which is allowed to become tacky. The mould 50 is then coated with a first layer of a polyester (not shown) and a first layer 61 of glass fibre is placed over the relatively short length 56. The layer 61 is coated with a second layer of a polyester. This is followed by a second layer 62 of glass fibre which is placed over the first layer 61 but has a length sufficient to cover the vertical wall 55.
Next, a third layer 63 of glass fibre is placed over the relatively long length 51 having a length sufficient to cover the sloping wall 52 and the base54.
Next, the layer 63 is coated with a third layer of a polyester and a fourth layer 64 of glass fibre is placed over the third layer 63 so as to cover it completely. This is followed by coating of the second layer 62 with a fourth layer of a polyester and the placement of a fifth layer 65 of glass fibre over the second layer 62 but excluding the vertical wall 55. The fifth layer 65 is coated with a fifth layer of a polyester. The thickness of each of the layers 61-65 is approximately 0.45mm.
A sixth layer 66 of glass fibre is now placed over the fifth layer 65 having a length sufficient to cover the well 53 and extend a distance along the relatively long length 51.
Then a seventh layer 67 of glass fibre is now placed over the fourth layer 64 or substantially the length of the fourth layer so as to overlap the sixth layer 66.
The polyester layer is preferably a pre-accelerated non-saturated amino polyester resin with a built-in inhibitor which, just prior to use, has been combined with an organic peroxide which, by chemical reaction, forms a gel and subsequently cures the polyester resin.
Now, with respect to the first mould 50, a core filler 68 having substantially the shape and configuration of the well and the side walls thereof is placed thereon. The filler 68 may comprise any suitable material such as timber, PVC, cork, marine ply or a urethane.
The second mould 70 is inverted and placed in mirror image relationship relative to, and on top of, the first mould 50 and the combination placed in a press (not shown) operating a pressure of between 68.9kPa and 206.5kPa (10 and 30psi), preferably 172.3kPa (25psi) for a period of between 70 and 80 minutes, preferably 75 minutes and at a temperature of between 170C and 22"C, preferably 200C.
At the end of the desired period, the combination is removed from the press, the thus formed door 90, is removed from the moulds 50, 70 and subject to a finishing stage.
The door 90 thus formed has a blade 91, a spine 92 and a fin 93. The fin 93 enables mounting of the door for swing operation. The spine 92 provides for substantially all of the mass of the door 90 whereas the blade 91 provides substantially all of the door per se.
The invention is not limited by or to the specific embodiment described which can undergo considerable variation without departing from the scope of the invention.
Claims (5)
1. A method for the manufacture of a door which method comprises the steps of: (a) providing a first mould and second mould which
are identical to each other, each mould, having
in cross-section a relatively long length of
substantially constant cross-section leading to
a downwardly sloping part which terminates in a
well the opposite side of which comprises a
substantially vertical wall leading to a
relatively short length of substantially
constant cross-section and having the same
thickness as that of the relatively long length; (b) coating the surface of each mould and associated
wall with a layer of isophthalic gel coat and
allowing it to cure until tacky; (c) coating the surface of each mould with a first
layer of a polyester; (d) laying a respective first layer of glass fibre
along the relatively short length;; (e) coating the first layer of glass fibre with a
second layer of a polyester; (f) laying a respective second layer of glass fibre
along the first layer of glass fibre which
second layer has a length sufficient to cover
the vertical wall; (g) laying a respective third layer of glass fibre
along the relatively long length which layer has
a length sufficient to cover the sloping part
and the well; (h) coating the third layer of glass fibre with a
third layer of a polyester; (i) laying a respective fourth layer of glass fibre
on top of the third layer so as to substantially
cover it; (j) coating the fourth layer of glass fibre with a
fourth layer of a polyester; (k) laying a respective fifth layer of glass fibre
over the second layer but excluding the vertical
wall; (1) coating the fifth layer of glass fibre with a
fifth layer of a polyester;; (m) laying a respective sixth layer of glass fibre
over the fifth layer said sixth layer having a
length sufficient to cover the well and extend a
distance along the relatively long length; (n) laying a respective seventh layer of fibreglass
over the fourth layer or substantially the
length of the fourth layer so to overlap the
sixth layer; (o) in the case of the first mould, providing a
filler core layer having substantially the shape
and configuration of the well and the side walls
thereof; (p) placing the second mould on top of the first
moulds in mirror image relationship to form a
combination mound; (q) placing the combination mould in a press at
between 68.9kPa-206.8kPa (10-30psi); (r) removing the combination mould from the press
and removing the thus formed door therefrom; and (s) finishing the door.
2. A method as claimed in claim 1 wherein the combination mould is subject to a pressure in step (q) for a period of between 70 and 80 minutes, preferably 75 minutes.
3. A method as claimed in claim 1 or 2 wherein the combination mould is subject to a pressure in step (q) at a temperature of between 170C and 220C, preferably 200C.
4. A method as claimed in any of claims 1-3 wherein the polyester layer comprises a pre-accelerated non-saturated amino polyester resin with a built-in inhibitor together with an organic peroxide which serves to provide a gel and subsequently cure the polyester resin.
5. A method for the manufacture of a door substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IES950418 IES66088B2 (en) | 1995-06-07 | 1995-06-07 | A method of manufacture of a swing door |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB9611709D0 GB9611709D0 (en) | 1996-08-07 |
| GB2301791A true GB2301791A (en) | 1996-12-18 |
| GB2301791B GB2301791B (en) | 1998-08-19 |
Family
ID=11040782
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9611709A Expired - Fee Related GB2301791B (en) | 1995-06-07 | 1996-06-05 | A method of manufacture of a swing door |
Country Status (2)
| Country | Link |
|---|---|
| GB (1) | GB2301791B (en) |
| IE (1) | IES66088B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2836949A1 (en) * | 2002-03-05 | 2003-09-12 | T L T | Plastic door e.g. for building with strict hygiene regulations has reinforcing member welded to door panel to form one-piece assembly |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1250075A (en) * | 1969-02-06 | 1971-10-20 | ||
| GB2224969A (en) * | 1988-09-12 | 1990-05-23 | Tetronel Limited | Improvements in and relating to the manufacture of laminates |
| EP0437395A2 (en) * | 1990-01-10 | 1991-07-17 | Cray Valley Sa | Method of manufacturing a moulded article from thermohardening plastic in corporating a decorative layer |
| WO1995013916A1 (en) * | 1992-05-14 | 1995-05-26 | Minster Composite Industries Limited | Panel |
-
1995
- 1995-06-07 IE IES950418 patent/IES66088B2/en not_active IP Right Cessation
-
1996
- 1996-06-05 GB GB9611709A patent/GB2301791B/en not_active Expired - Fee Related
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1250075A (en) * | 1969-02-06 | 1971-10-20 | ||
| GB2224969A (en) * | 1988-09-12 | 1990-05-23 | Tetronel Limited | Improvements in and relating to the manufacture of laminates |
| EP0437395A2 (en) * | 1990-01-10 | 1991-07-17 | Cray Valley Sa | Method of manufacturing a moulded article from thermohardening plastic in corporating a decorative layer |
| WO1995013916A1 (en) * | 1992-05-14 | 1995-05-26 | Minster Composite Industries Limited | Panel |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2836949A1 (en) * | 2002-03-05 | 2003-09-12 | T L T | Plastic door e.g. for building with strict hygiene regulations has reinforcing member welded to door panel to form one-piece assembly |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2301791B (en) | 1998-08-19 |
| GB9611709D0 (en) | 1996-08-07 |
| IES950418A2 (en) | 1995-12-13 |
| IES66088B2 (en) | 1995-12-13 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 20100605 |