GB2343476A

GB2343476A - A panel with plastics inner filling

Info

Publication number: GB2343476A
Application number: GB9924138A
Authority: GB
Inventors: K A Harris
Original assignee: AUTO PLAS INTERNATIONAL LIMITE
Current assignee: AUTO PLAS INTERNATIONAL LIMITE
Priority date: 1998-10-26
Filing date: 1999-10-13
Publication date: 2000-05-10
Anticipated expiration: 2019-10-13
Also published as: GB2343476B; GB9924138D0; GB9823214D0

Abstract

The assembly comprises an inner framework 2 defining both the general periphery of the panel or article and facing sheets 9, 10 which define a space 3, a filling of plastics material totally filling the space 3. This plastic material filling can sandwich a sheet of stiffening material 13. A plastics mouldings 14 may covers exposed parts of the framework 2, said mouldings being of such profile as to facilitate the fitting of the door or article into its location of application. At least one of the facing sheets 9,10 may be covered with a further sheet or sheets 19, 20 preferably made of plastics material. The inner framework 2 may be partially cut away to provide a lengthwise extending recess 7, and the further sheets 19, 20 and plastic moulding 14 can totally enclose the framework.

Description

PANEL CONSTRUCTION This invention relates to the production of large area panels having a specified required form.

In particular, but not exclusively, the present invention is concerned with the production of panels suitable for use in the construction of buildings, and more particularly to the construction of externally and internally fitting doors.

Historically both externally and internally fitting doors for both commercial and residential buildings have been formed from wood. Such doors, as is well known, are constructed in a very wide range of styles and dimensions with or without openings for windows or for other purposes.

In relation to the utilisation of woods as the fabrication materials, such use has been accompanied by two basic bothersome factors one associated with the upkeep and the preservation of the wood itself and the other factor with the maintenance of the everyday appearance of the wood.

In relation to the first mentioned topic the principal problem has been avoiding and, if possible, eliminating ongoing physical decay and rotting of the woods, and in relation to the second topic the ongoing inconvenience of the need regularly to refurbish the external surfaces of the wood by appropriate forms of surface coating and decoration.

As is well known, the ongoing, for example, need regularly to repaint or otherwise treat a door is not only costly but inherently involves the creation of unpleasant aromas, dirt and dust with the consequential risk of damage to the contents of a room such as, for example, electronic equipment or other equipment liable to damage through ingress of dusts and aromatics.

With a view to the elimination of such problems it has become a common present day practice to replace wooden doors, particularly externally used doors, with doors formed from plastics materials and commonly plastics commonly referred to as UPVC.

Presently such doors are constructed in many forms and frequently are intended to be replias of the wooden doors they are replacing.

In relation to the presently used plastics doors it has been noted that by and large such plastics doors involve the inherent problem, in relation to the sturdiness of the door, of not being generally able to withstand forces arising from attempts of forcible entry through the door.

In addition, the known door constructions are such as not to be able to withstand twist and induced distortion forces.

It is an object of the present invention to provide an improved construction for a large area panel or article such as a door forming structure.

Broadly, according to a first aspect of the invention there is provided an extended area panel or article comprising an inner framework defining the general periphery of the panel or article and also serving to receive the edge regions of facing sheets in such manner as to collision at least the inner marginal regions of the framework thereby to define a space defined by the inner faces of the facing sheets and the inner regions of the framework, a filling of plastics material totally filing the space.

Preferably a plastics moulding is provided for covering exposed parts of the framework or selected parts of the framework, said moulding being of such profile as to facilitate the fitting of the door or article. into its location of application.

In a particular construction at least one of the aforesaid facing sheets is covered with a further sheet.

Preferably, two such further sheets are provided.

Conveniently each such further sheet comprises plastics material.

For a better understanding of the invention and to show how to carry the same into effect reference will now be made to the accompanying drawing that very schematically illustrates in fragmentary cross section a first embodiment is a panel or article construction incorporating the concepts of the present invention.

As may be seen from the drawing the panel or article 1 as represented by the Figure includes a main frame 2 having a generally rectangular cross section with an inner surface 3 and outer surface 4 parallel to the inner surface 3, and upper and lower (as shown in the Figure) surfaces 5 and 6.

The outer surface 4 is partially cutaway to provide a lengthways extending recess 7.

The peripheral edges regions of first and second main sheets 9 and 10 are respectively attached to the upper and lower surfaces of the framework 2. As will be noted the mounting of the sheets totally closes in the framework to provide a closed in space 8 defined by the sheets 9,10 and the inner surface 3 of the framework 2.

This space 8 is filled with plastics material.

In practice, in the embodiment illustrated the plastics material filling comprises two separate relatively thick sheets/layers 11,12 of plastics material sandwiching a relatively thin sheet 13 of stiffening material conveniently formed by an appropriate plastics material. The plastics sheets/layers 11, 12 are firmly attached to the stiffening sheet 13 by any appropriate method i. e., by the use of adhesives or by thermosetting action produced between the facing surfaces of the plastics infill and the stiffening material.

In the embodiment shown a profile plastics moulding 14 is secured to the outer surface of the framework 2. As will be noted the moulding conforms generally to the external shape of the surface of the framework 2. As will be noted the hall of the moulding engages with the surfaces 15, 16 and 17 produced by the formation of the recess 7.

The moulding 14 is firmly secured to the outer surface of the framework by an appropriate adhesive/filler that ensures that individual details and/or parts of the moulding are accommodated during the mounting of the moulding to the framework.

The sheets 9 and 10 are covered with further plastic sheets 19 and 20 respectively. The dimensions of the sheets 19 and 20 are such that the external surfaces of the moulding lying in the plane of the outer surfaces of the sheets 9 and 10 are covered.

It has been found that with the construction as above described the panel, i. e., door is considerably stiffer than a purely plastics formed door of similar dimensions.

In addition, it will be noted that the amount of plastics material utilised for the formation of the moulding is considerably reduced as compared with the quantity of plastics involved in the formation of a totally plastics door.

With the above discussed construction it will be noted that the framework 2 is conveniently formed from a multilayer plywood. Furthermore, it will be noted that the framework is totally enclosed i. e., effectively encapsulated by the plastics moulding 14 and the plastics sheets 19 and 20. Thus the framework is totally protected from exposure.

In a modified construction (not shown) the framework is lengthways cutback to provided location recesses extending the total length of inner margins of the upper and lower regions of the frame work to receive the marginal edges of the sheets 9 and 10. These recesses are so dimensioned that the outer surfaces of the sheets 9 and 10 are flush with the remaining part of the aforesaid upper and lower surfaces of the framework.

In the event that fire retardent properties are considered desirable the sheets/layers 11 and 12 and any replacement single sheet/layer can comprise a phenolic foam.

It will be understood, that in relation to constructions in which it is desired to produce a panel in which the peripheral outermost faces of the framework remain visible for what ever reason, i. e., for cosmetic reasons of appearance or other reasons the plastics moulding on the door surround can be omitted. It will be appreciated that with this embodiment the plastics filling 8 would shill be provided together with the large sheets of plastics.

It is also possible to utilise the concepts of the invention in constructions in which the two plastics sheets/layers 12 and 12 are replace by a single thicker sheet/layer (not shown in the Figure) of plastics materials.

Conveniently the sheets/layers I I and 12 and any single replacement layer/sheet can be of a foamed form of plastics material In the event that fire retardent properties are considered desirable the sheetsAayers 11 and 12 and any replacement single sheetAayer can comprise a phenolic foam.

Claims

CLAIMS 1 An extended area panel or article comprising an inner framework defining both the general periphery of the panel or article and serving to receive the edge regions of facing sheets in such manner as to collision at least the inner marginal regions of the framework thereby to define a space defined by the inner faces of the facing sheets and the inner regions of the framework, a fitting of plastics material totally filing the space,
2. An extended area panel or article, as claimed in claim 1, and wherein a plastics moulding is provided for covering exposed parts of the framework or selected parts of the framework, said moulding being of such profile as to facilitate the fitting of the door or article into its location of application.
3 An extended area panel or article as claimed in claim I or 2, and wherein at least one of the aforesaid facing sheets is covered with a further sheet.
4 An extended area panel or article as claimed in claim 3, and wherein each such further sheet comprises plastics material.
5. An extended area panel or article as claimed in claim 1 2,3 or 4, and wherein the panel includes a main frame having a generally rectangular cross section with an inner surface and outer surface arranged parallel to the inner surface, and upper and lower surfaces, said outer surface being partially cutaway to provide a lengthways extending recess, and wherein first and second facing sheets are respectively attached to the upper and lower surfaces around the peripheral regions of thereof, the arrangement being such that the mounting of the facing sheets totally closes in the framework to provide a closed in space defined by the facing sheets and the inner surface of the framework, said space being filled with the plastics material.
6. An extended areas panel or article as claimed in claim 1, 2,3,4 or 5"and wherein the plastics material filling comprises two separate relatively thick sheets/layers of plastics material sandwiching a relatively thin sheet of stiffening material formed by an appropriate plastics material and wherein the plastics sheets/layers are firmly attached to the stiffening sheet by the use of adhesives or by thermosetting action produced between the facing surfaces of the plastics infill and the stiffening material.
7. An extended area panel or article as claimed in any one of the preceding claims, and wherein the plastics material filling comprises two separate relatively thick sheets/layers of plastics material sandwiching a relatively thin sheet stiffening material conveniently formed by an appropriate plastics material, and wherein the plastics sheets/layers are firmly attached to the stiffening sheet by any appropriate method i. e., by the use of adhesives or by thermosetting action produced between the facing surfaces of the plastics infill and the stiffening material.
8. An extended area panel or article as claimed in any one of the preceding claims and wherein the framework is lengthways cutback to provided location recesses extending the total length of inner margins of the upper and lower regions of the framework to receive the marginal edges of the first and second sheets, and wherein the recesses are so dimensioned that the outer surfaces of the first and second sheets are flush with the remaining part of the aforesaid upper and lower surfaces of the framework.

9 An extended area panel or article as claimed in any one of the preceding claims and wherein the filling of plastics material includes a single sheet/'layer of plastics material. 10 An extended area article as claimed in claim 9, wherein the plastics filling material comprises a foamed form of plastics material.

11 An extended area panel or article substantially as thereinbefore described with reference to t he Figure of the accompanying drawing.