GB2393932A - Surface preparation - Google Patents

Surface preparation Download PDF

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Publication number
GB2393932A
GB2393932A GB0221677A GB0221677A GB2393932A GB 2393932 A GB2393932 A GB 2393932A GB 0221677 A GB0221677 A GB 0221677A GB 0221677 A GB0221677 A GB 0221677A GB 2393932 A GB2393932 A GB 2393932A
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GB
United Kingdom
Prior art keywords
relatively flexible
forming
frame
plastics
component
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
Application number
GB0221677A
Other versions
GB2393932B (en
GB0221677D0 (en
Inventor
Ernest Kenneth Hammond
Nicholas Guy Clarke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
POLYMER ENGINEERING Ltd
Original Assignee
POLYMER ENGINEERING Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by POLYMER ENGINEERING Ltd filed Critical POLYMER ENGINEERING Ltd
Priority to GB0221677A priority Critical patent/GB2393932B/en
Publication of GB0221677D0 publication Critical patent/GB0221677D0/en
Publication of GB2393932A publication Critical patent/GB2393932A/en
Application granted granted Critical
Publication of GB2393932B publication Critical patent/GB2393932B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/02—Preparation of the material, in the area to be joined, prior to joining or welding
    • B29C66/022—Mechanical pre-treatments, e.g. reshaping
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0053—Moulding articles characterised by the shape of the surface, e.g. ribs, high polish
    • B29C47/02—
    • 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
    • B29C55/00—Shaping by stretching, e.g. drawing through a die; Apparatus therefor
    • B29C55/30—Drawing through a die
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/52—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive
    • B29C65/54—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the way of applying the adhesive between pre-assembled parts
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
    • B29C70/525—Component parts, details or accessories; Auxiliary operations
    • 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
    • B29C70/688—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 the inserts being meshes or lattices
    • 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
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • 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
    • E06B3/82—Flush doors, i.e. with completely flat surface
    • E06B3/822—Flush doors, i.e. with completely flat surface with an internal foursided frame
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/32—Measures for keeping the burr form under control; Avoiding burr formation; Shaping the burr
    • B29C66/322—Providing cavities in the joined article to collect the burr
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/737—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined
    • B29C66/7375—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured
    • B29C66/73755—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
    • B29C66/73756—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the state of the material of the parts to be joined uncured, partially cured or fully cured the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized the to-be-joined areas of both parts to be joined being fully cured
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7394—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset
    • B29C66/73941—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoset characterised by the materials of both parts being thermosets
    • 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
    • B29L2007/00—Flat articles, e.g. films or sheets
    • B29L2007/002—Panels; Plates; Sheets
    • 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
    • B29L2012/00—Frames
    • 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
    • B29L2024/00—Articles with hollow walls
    • 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
    • B29L2031/001—Profiled members, e.g. beams, sections
    • B29L2031/003—Profiled members, e.g. beams, sections having a profiled transverse cross-section
    • 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
    • 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
    • E06B2003/7059—Specific frame characteristics
    • E06B2003/7082—Plastic frames

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Securing Of Glass Panes Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention comprises a method of forming a component 1 with a surface 3 suitable for adhesion, the method comprising embedding a relatively flexible material 2 in a plastics material and forming the component 1 from the plastics material, whereby the relatively flexible material 2 is embedded in and covers a surface of the so-formed component 1 in a region where it is intended to adhere a further object. The component may be a frame member 1 or skin member 6 for the formation of a door. The frame member 1 may be pultruded and the relatively flexible material may be an open weave fabric 2. The material 2 is removed from members 1 and 6 to reveal a clean, abraded surface 3,4 which is suitable to adhere members 1 and 6 together to form the door. Methods of forming a door have also been claimed.

Description

r Surface Preparation 5 This invention relates to the preparation of a
surface of a component of, say, a door. It is known that components formed by processes such as moulding, extrusion or pultrusion may be used for a variety of purposes. Such processes are common in 10 industries which use plastics materials. One such industry is the manufacture of doors for external and internal use.
Various patents have been published which propose the use of plastics materials to fabricate doors. In some such patents, plastics materials are used to 15 manufacture a frame or chassis, a foam core and a panel which covers each major surface of the door.
In our co-pending patent application no. 0200498.4 (published as GB-A 2371075) we describe and claim, inter alla, a method of forming a door comprising 20 pultruding a synthetic material having a low coefficient of thermal expansion to form lengths, assembling the lengths to form a framework, and attaching panels to opposed faces of the so-assembled framework.
Pultrusion is a process by which continuous elongate fibres e.g. one of glass, 25 carbon or aramid, Terylene, Nylon or hemp are impregnated into a t'hermoset resin and pulled through a preformer into a heated die. The shape of the end product is determined by the die, the heat causing the resin to polymerise, e.g. cross link. By
. using pultrusion, one can obtain lengths which can be cut to size and then joined together to form a frame. The lengths have a good strength/weight ratio. In the context of doors, it is useful to pultrude thermoses material to form the frame because the so-formed frame will consequently have a low coefficient of thermal expansion. If 5 the panels are made from the same material, or of a material having the same property, one can have a door fabricated from components having a substantially uniform coefficient of thermal expansion.
A problem sometimes occurs in moulding, extruding and pultruding operations 10 wherein a surface of a component, to which it is desired to adhere an object, is unsuitable for adhesion. The surface will either be too uneven to provide substantial contact between the surface and the object to be adhered or too smooth to key the adhesive. Preparation of such surfaces subsequent to formation of the component is costly and timeconsuming.
Accordingly, it is an object of this invention to provide a method to ensure that a surface of a component, to which an object is to be adhered, is suitable for such adhesion. 20 A first aspect of the invention provides a method of forming a component with a surface suitable for adhesion, the method comprising embedding a relatively flexible material in a plastics material and forming the component from the plastics material, whereby the relatively flexible material is embedded in and covers a surface of the so formed component in a region where it is intended to adhere a further object.
The forming step of the method may comprise co-pultruding the plastics material with the relatively flexible material or co-extruding the plastics material with the relatively flexible material.
5 As one alternative, the forming step of the method may comprise moulding, for example Resin Transfer Moulding (RTM) or the like.
The relatively flexible material is preferably an open weave fabric. The plastics material is preferably a thermoses plastics material and is preferably selected from one JO of GRP, vinyl ester, polyester, phenolic or epoxy resin.
The component may be an integer of a frame, for example a frame from which a door is to be constructed or the component may be a panel to provide the fascia of a door. Both panels and frame integers may be constructed using the method.
A second aspect of the invention provides a method of forming a door, the method comprising co-pultruding a plastics material with a relatively flexible material to form a frame member wherein the relatively flexible material is at least partially embedded within the surface of the frame member, cutting the frame member to length 20 and joining a plurality of frame members together to form a frame, removing the relatively flexible material from the surface and adhering a panel to that surface.
A yet further aspect of the invention provides a method of forming a door, the method comprising moulding a plastics material to form a panel for a door with a 25 relatively flexible material embedded within the surface of the panel along the edges thereof, removing the relatively flexible material from the surface and adhering the panel to a frame.
t Preferably the open weave fabric is formed from glass fibres or from Terylene.
In a preferred embodiment, the open weave fabric has from 3.9 - 11.8 threads per centimetre (10 to 30 threads per inch) in both the warp and weft, most preferably 7.8 5 threads/cm (20 threads per inch) in both directions.
A further aspect of the invention provides a method of forming a door, the method comprising: À forming frame members by pultruding plastics material; 10 À forming a core and assembling frame members about edges of the core; À forming a plastics skin to be applied over the frame and core; and À joining the skin to at least the frame by an adhesive and characterized by including a detachable layer on a surface of each frame member or the skin or both to provide surface deformations to the underlying 15 plastics surface, the detachable layer being removed prior to application of the adhesive, the deformations providing sites to key the adhesive whereby the strength of the bond formed exceeds that of the frame or the skin.
The invention also comprises a component for a door, and a door formed by the 20 above-described methods.
In order that the invention may be more fully understood, it will now be explained by way of example only and with reference to the accompanying drawings, in which: Figure 1A is a perspective view of a frame member formed by the invention;
Figure 1B is the frame member of Figure 1A after partial removal of a surface layer; and Figure 2 is a transverse section through part of a door made in accordance with the invention.
Referring to the Figures, there is shown a profile 1 formed from pultruded thermoses plastics material. The profile 1 is co-pultruded with an open-weave fabric material 2 to cover a surface 3 of the profile 1, the fabric material 2 being fed into the pultrusion die with the plastics material.
Rovings of elongate fibres are advanced towards the die head and, just before entering the head, are sprayed or otherwise soaked in or with resin. The open-waeve fabric material 2 is fed to the die head to enter with the resin soaked rovings. The rovings with the fabric material 2 emerge from the die head having been forced to 15 adopt the desired shape. During passage through the head, the fabric material 2 is displaced towards the surface of the plastics resin by the rovings.
Consequently, the fabric material 2 is located just below the surface 3 of the profile 1 and is visible.
Lengths of profile 1 are cut to the appropriate size and adhered together to form a rectangular framework. The lengths of profile 1 may be assembled around a core material 5.
25 A skin 6 is formed from a thermoses material by RTM. An open-weave fabric material is placed within the mould prior to the RTM operation at the edges of the
mould. During RTM, the skin 6 is formed with the open weave fabric material being embedded therein at the edges of the skin 6.
Arrows A and B indicate the extent to which the open weave fabric 2 covers the 5 surface of the profile 1 and the skin 6.
Prior to assembly of the profile 1 and skins 6 to form a door, the open weave fabric material 2 is removed from the assembled profiles 1 and skins 6 to reveal a clean, abraded surface 3, 4 which is suitable to adhere the components 1, 6 together.
10 The surface 3, 4 is of exposed virgin material. Any loose material from the profile 1 and skin 6 is removed by rubbing or blowing air over the surface thereof. An adhesive, such as an acrylate or polyurethane, is spread over the areas to be adhered 3, 4 and the two components 1, 6 are brought together.
15 Because the material 2 is open weave, the plastics material is able to flow between the threads of the material 2 during the component forming process. This ensures that the surface of the profile and skin, subsequent to material 2 removal, is formed with a plurality of raised "islands". The height of these "islands" is typically 0.254 - 0.381 mm, although larger or smaller heights can be achieved by altering the 20 thickness of the material. Therefore, the islands and associated recesses provided on the respective surfaces 3, 4 ensure that each surface 3, 4 is eminently suitable to key an adhesive.
It has been found in delamination and shear tests that the strength of the 25 adhesive bond formed is so great in the inventive method that the profile 1 or skin 6 will fail before the adhesive bond.
It will further be appreciated that by forming a component with the fabric layer 2 adjacent a surface to be adhered to, that surface 3, 4 is kept both clean and dry.
Only one of the components (profile 1 and skin 6) need be formed with the 5 fabric layer 2.

Claims (16)

i Claims
1. A method of forming a component with a surface suitable for adhesion, the method comprising embedding a relatively flexible material in a plastics material and 5 forming the component from the plastics material, whereby the relatively flexible material is embedded in and covers a surface of the so-formed component in a region where it is intended to adhere a further object.
2. A method according to Claim 1, wherein the forming step comprises copultruding 10 the plastics material with the relatively flexible material.
3. A method according to Claim 1, wherein the forming step comprises coextruding the plastics material with the relatively flexible material.
15
4. A method according to Claim 1, wherein the forming step comprises moulding, for example Resin Transfer Moulding (RTM) or the like.
5. A method of forming a door, the method comprising co-pultruding a plastics material with a relatively flexible material to form a frame member wherein the 20 relatively flexible material is at least partially embedded within the surface of the frame member, cutting the frame member to length and joining a plurality of frame members together to form a frame, removing the relatively flexible material from the surface and adhering a panel to that surface.
25
6. A method of forming a door, the method comprising moulding a plastics material to form a panel for a door with a relatively flexible material embedded within the
. surface of the panel along the edges thereof, removing the relatively flexible material from the surface and adhering the panel to a frame.
7. A method of forming a door, the method comprising: 5 À forming frame members by pultruding plastics material; À forming a core and assembling frame members about edges of the core; À forming a plastics skin to be applied over the frame and core; and À joining the skin to at least the frame by an adhesive and characterized by including a detachable layer on a surface of each frame To member or the skin or both to provide surface deformations to the underlying plastics surface, the detachable layer being removed prior to application of the adhesive, the deformations providing sites to key the adhesive whereby the strength of the bond formed exceeds that of the frame or the skin.
15
8. A door formed by the method of Claim 5 or Claim 6 or Claim 7.
9. A plastics component for a door having a relatively flexible material embedded in a surface thereof.
20
10.A component according to Claim 9, wherein the relatively flexible material is an open weave fabric.
11. A component according to Claim 10, wherein the open weave fabric is formed from glass fibres or from Terylene.
12.A component according to Claims 10 or 11, wherein the open weave fabric has from 3.9 - 11.8 threads per centimetre (10 to 30 threads per inch) in both the warp and weft, most preferably 7.8 threads/cm (20 threads per inch) in both directions.
5
13.A component according to Claim 10, 11 or 12 formed from a thermoses plastics material, preferably selected from one of GRP, vinyl ester, polyester, phenolic or epoxy resin.
14. A component according to any of Claims 9 to 13 in the form of a frame member.
15. A component according to any of Claims 9 to 13 in the form of a panel.
16. A method substantially as hereinbefore described.
15 17. A component substantially as hereinbefore described with reference to Figures 1A, 1 B and 2.
LS/CM/P03646GB
20 13 September 2002
l Amendments to the claims have been filed as follows 1. A method of forming a component with a surface suitable for adhesion, the method comprising embedding a relatively flexible open weave fabric material in a plastics 5 material and forming the component from the plastics material, whereby the relatively flexible material is embedded in and covers a surface of the so-formed component in a region where it is intended to adhere a further object.
2. A method according to Claim 1, wherein the forming step comprises copultruding 10 the plastics material with the relatively flexible, open weave fabric material.
3. A method according to Claim 1, wherein the forming step comprises coextruding the plastics material with the relatively flexible open weave fabric material.
15. A method substantially as hereinbefore described.
15
16. A component substantially as hereinbefore described with reference to Figures 1A, 1 B and 2.
15 4. A method according to Claim 1, wherein the forming step comprises moulding, for example Resin Transfer Mouiding (RTM) or the like a. A. metr!o-i ol: o.ming a dOQ!-, tire me.!-!oo v,-np,-ising co-pultruding a plastics material with a relatively flexible open weave fabric material to form a frame 20 member wherein the relatively flexible open weave fabric material is at least partially embedded within the surface of the frame member, cutting the frame member to length and joining a plurality of frame members together to form a frame, removing the relatively flexible open weave fabric material from the surface and adhering a panel to that surface.
6. A method of forming a door, the method comprising moulding a plastics material to form a panel for a door with a relatively flexible open weave fabric material embedded within the surface of the panel along the edges thereof, removing the relatively flexible open weave fabric material from the surface and adhering the 5 panel to a frame.
7. A method of forming a door, the method comprising: À forming frame members by pultruding plastics material; À forming a core and assembling frame members about edges of the core; 10 À forming a plastics skin to be applied over the frame and core; and À joining the skin to at least the frame by an adhesive and characterized by including a detachable open weave fabric layer on a surface of each frame member or the skin or both to provide surface deformations to the underlying plastics surface, the detachable open weave fabric layer being removed prior to application of the adhesive, the deformations providing sites to key the adhesive whereby the strength Of the .,.,.;................
: _ _ _ 1 _ _
8. A door formed by the method of Claim 5 or Claim 6 or Claim 7.
9. A plastics component for a door having a relatively flexible open weave fabric material embedded in a surface thereof.
10. A component according to Claim 9, wherein the open weave fabric is formed from 25 glass fibres or from Terylene.
I 11. A component according to Claims 9 or 1 O. wherein the open weave fabric has from 3.9 - 11.8 threads per centimetre (10 to 30 threads per inch) in both the warp and weft, most preferably 7.8 threads/cm (20 threads per inch) in both directions.
5 12.A component according to Claim 9, 10 or 11 formed from a thermoses plastics material, preferably selected from one of GRP, vinyl ester, polyester, phenolic or epoxy resin.
13. A component according to any of Claims 9 to 12 in the form of a frame member.
14. A component according to any of Claims 9 to 12 in the form of a panel.
GB0221677A 2002-09-18 2002-09-18 Surface preparation Expired - Fee Related GB2393932B (en)

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US6962031B2 (en) * 2001-01-11 2005-11-08 Polymer Doors Limited Doors
EP1664661A2 (en) * 2003-09-10 2006-06-07 Ra Brands, L.L.C. Process for imprinting a composite ventilated rib
DE102015121325A1 (en) * 2015-12-08 2017-06-08 Koschmieder Bauelemente GmbH Door leaf and flush door unit

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US4492063A (en) * 1981-04-15 1985-01-08 Schock & Co. Gmbh Extruded plastics material hollow profiled strip for window frames, window frames produced from this type of profiled strips and method for the production of a window frame of this type
US4476174A (en) * 1981-10-02 1984-10-09 Tenex Corporation Composite plastic mat and method of forming same
EP0154121A1 (en) * 1984-02-18 1985-09-11 Continental Aktiengesellschaft Method of producing sealing strips and similar extruded profiles from rubber and/or rubber-like elastomers
JPS6162487A (en) * 1984-08-31 1986-03-31 日産自動車株式会社 Seat cushion pad
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GB2245922A (en) * 1990-06-05 1992-01-15 Colebrand Ltd A tile or sheeting
EP0461901A2 (en) * 1990-06-15 1991-12-18 Amcol International Corporation Bentonite composition structurally supported with flexible material and method
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DE4217934A1 (en) * 1992-05-30 1993-12-02 Burkhart Schurig Lightweight reinforced high strength foam filled component - contains grid pattern of flat e.g. steel or plastic strips embedded in the foam close to the surface exposed to tension stresses
WO1996012611A1 (en) * 1994-10-24 1996-05-02 Omniglass Ltd. Pultruded part with covering veneer
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US6962031B2 (en) * 2001-01-11 2005-11-08 Polymer Doors Limited Doors
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EP1664661A4 (en) * 2003-09-10 2008-02-13 Ra Brands Llc Process for imprinting a composite ventilated rib
DE102015121325A1 (en) * 2015-12-08 2017-06-08 Koschmieder Bauelemente GmbH Door leaf and flush door unit

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GB2393932B (en) 2006-07-19
GB0221677D0 (en) 2002-10-30

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Effective date: 20070918