GB2448611A - Methods of manufacturing a glass fibre door leaf - Google Patents

Methods of manufacturing a glass fibre door leaf Download PDF

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Publication number
GB2448611A
GB2448611A GB0807073A GB0807073A GB2448611A GB 2448611 A GB2448611 A GB 2448611A GB 0807073 A GB0807073 A GB 0807073A GB 0807073 A GB0807073 A GB 0807073A GB 2448611 A GB2448611 A GB 2448611A
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United Kingdom
Prior art keywords
core
blank
glass fibre
forming
article
Prior art date
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Application number
GB0807073A
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GB0807073D0 (en
Inventor
Robert Mackean Agnew
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Individual
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of GB0807073D0 publication Critical patent/GB0807073D0/en
Publication of GB2448611A publication Critical patent/GB2448611A/en
Withdrawn legal-status Critical Current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
    • 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
    • B29C70/70—Completely encapsulating 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
    • 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
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • 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
    • E06B3/7001—Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
    • 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
    • E06B3/7015—Door leaves characterised by the filling between two external panels
    • 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
    • E06B3/72—Door leaves consisting of frame and panels, e.g. of raised panel type
    • E06B3/725—Door leaves consisting of frame and panels, e.g. of raised panel type with separate hollow frames, e.g. foam-filled
    • 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
    • E06B3/72—Door leaves consisting of frame and panels, e.g. of raised panel type
    • E06B3/78—Door leaves consisting of frame and panels, e.g. of raised panel type with panels of plastics
    • 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
    • E06B3/86—Flush doors, i.e. with completely flat surface of plastics without an internal frame, e.g. with exterior panels substantially of plastics
    • 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
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
    • B29K2033/04—Polymers of esters
    • B29K2033/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/043—Skinned foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0016—Non-flammable or resistant to heat
    • 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
    • E06B3/7015—Door leaves characterised by the filling between two external panels
    • E06B2003/7023—Door leaves characterised by the filling between two external panels of foam type
    • 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
    • E06B2003/7049—Specific panel characteristics

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  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The invention relates to a method of forming extended area article such as a door leaf incorporated within a skin of glass fibre material by forming a blank/core 1 from a rigid form material, totally enclosing the blank/core 1 in a layer of fibreglass material, and impregnating the fibreglass material with resin to totally encapsulate the blank/core 1. The glass fibre material may comprise a plurality of woven layers. The blank/core 1 may be formed from a polyurethane blank/core, decoratively profiled (2 figure 1) so as to form a relief in the article. A later embodiment relates to a method of producing an extended area article comprising the steps of forming/profiling a core, encapsulating the core with glass fibre, placing the encapsulated core in a mould and injecting resin into the mould.

Description

* 2448611
METHODS OF MANUFACTURE OF EXTENDED AREA ARTICLES
This invention relates to the production/manufacture of extended area articles such as doors In particular this invention relates to the production of doors incorporating mouldable plastics materials.
In further particular the present invention is concerned with the manufacture of doors using a combination of manufacturing processes and stages that facilitates the production of doors of differing sizes that are based upon a basic standard sized structure that is appropriate for size ways and appearance modification.
As is well known doors irrespective of the purpose of the property into which they are to be fitted can be of various sizes and appearances.
Generally doors are made to a number of standard sizes so that they will readily fit into a suitable standard sized door framing.
Hitherto doors and other extended area articles incorporating both structural and decorative elements such elements have been produced separately and subsequently assembled, e.g., combined, to produce an article incorporating the structural and decorative element.
This latter method of production is expensive and can lead to failures in service due to moisture ingress or external damage reducing the integral strength of the component.
It is an object of the present invention to provide an improved process for the production of extended area articles such as a door as used in commercial and private housing or other properties of more specialist constructions.
It is a further object of the present invention to provide a combination of various manufacturing stages/ processes that combines to facilitate the production of doors in general and additionally to facilitate the production of doors that are regarded as none standard.
A further aspect of the invention provides method of producing en extended area article, including the steps of forming/profiling a blank/core of shape and size of a required article, encapsulating the thus form blank/core within a layer of glass fibre material such that the blank/core is totally enclosed within the glass fibre,, introducing the encapsulated blank/core into an appropriately shaped and profiled enclosing mould, and injecting a resin into the mould such that the resin flows through the glass fibre enabling the resin to cure to form a continuous outer skin to the blank/core, Conveniently the blank/core is formed from a foamed closed rigid cell foam.
In a particular anangement the blank/core is in the form of a pack/stack of glass fibre material comprising a plurality of layers of of glass fibre material, For a better understanding of the invention and to show how to carry the same into effect reference will be made to the accompanying drawings in which:-Figure 1 very schematically illustrates a rectangular core/blank of an article cut from a block of foamed closed rigid cell foam; Figure 2 very schematically illustrates a blank/core for a door that has been profiled; -Figure 3, very schematically illustrates in section the blank/core of Figures 1 and 2 when encapsulated within glass fibre material; and Figure 4 very schematically illustrates a resin injection stage following introduction of the blank/core and glass fibre layer within a mould.
For the purposes of discussion a sequence of steps/stages in the production of a simple basic design for a door will be considered in relation to the schematic Figures ito 4.
Referring now to Figure 1 a basic door fonrnng shape is produced from a rectangular blank/core 1 formed from a closed cell rigid foam, the blank being conventionally cut from a larger block (not shown) and serving to provide the core of the required door.
The blank/core 1 is then machined to an accurate thickness and cut to the particular size required. For example, such that it provides a standard size of door.
15.If desired the blank/core can be provided with decorative profiling 2 as is indicated in Figure 2. At this stage the profiling provides the blank/core with so called relief panels. It will be understood that the shape and positioning of the relief panels can be as desired for a particular door construction.
The blank/core is then totally encapsulated/wrapped within a layer of a glass fibre material usually fabric.
The glass fibre covering can be formed from a single piece of material or from two or more pieces of the material.
In either case the blank/core is totally enclosed within the layer.with the edge regions of the layer firmly connected to the associated edge regions of the blank I by means such as disclosed in co-pending Application entitled Methods of Locating Sheet Material. This is to ensure that no part of the blank/core I and any framing present is exposed, and that no joints between the marginal edges of the layers are exposed.
Figure 3 very schematically illustrates the blank/core I when encapsulated/wrapped in the layer 3 of the the glass fibre fabric.
The blank/core I together with its covering of glass fibre fabric 3 is placed into a mould whose interior surfaces conforms to the profiled shaping of the blank thereby ensuring that the layer 3 conforms to the profiling of the blank/core.
Resin is injected into the mould from a convenient location or locations of the mould in such manner that the resin is able to flow through the glass fibre between the mould surface and the outside of the foam blank/core. During this part of the process the resin injection is such as to ensure that all of the glass fibre is subjected to the action of the resin.
The resin cures/sets as a result of chemical action and in so doing very firmly bonds the glass fibre layer 3 to the blank/core 1.
The blank/core I with the encapsulating layer of glass fibre material is then removed from the mould. The resulting moulding provides a rigid hard door leaf.
At this stage it should be noted that the door leaf has an outer skin that is continuous over the various surfaces and also around the edge regions of the blank/core and is formed from the same material throughout without any exposed joining seams or the like. Therefore there is no likelihood of dc-lamination of the skins.
in practice, it has been found that a door leaf produced as above discussed has high strength and and rigidity as compared with a door leaf produced by a known method such one using two glass fibre layers which are then glued. bonded or screwed to a wooden or plastic sub frame around the edge which forms the edge of the door, The cavity in the middle is then filled with a liquid which foams to expand and fill up the cavity in the middle.
In relation to the method of the present invention for producing a standard door leaf it is possible readily to vazy the thickness of the layer of the glass fibre and also to skin to change the properties of the product For example, a door leaf of said basic overall size could be manufactured with a very much thicker glass fibre skin than is generally used. This can be readily achieved by reducing the thickness of the blank/core I and correspondingly increasing the thickness of the glass fibre material used to form the encapsulating skin The provision of a thicker glass fibre skin forming layer has been found significantly to increase the strength and the rigidity of the door leaf as compared with the above mentioned previously used method.
In an alternative construction the blank/core I as previously discussed may be replaced by a replacement core' in the form of a pack' of glass fibre material made up from a pluraiLty of layers of glass fibre material (fabric). For such a situation the weave of the glass fibre fabric would be chosen in the light of the intended function of the door leaf In practice the user properties of the doors produced by the proposals of the present invention makes it is possible to produce doors intended for a particular function For example, by using an appropriate type of glass fibre reinforcement material and using an appropriate resin i.e., by changing it from a polyester, * . -6-epoxy, acrylic type of resin to a phenolic resin it is possible to produce what appears to be exactly the same product but with a good fire resistance and fire rated capability.
In practice, since glass fibre fabrics are available in a variety of different weaves.
it is possible by selection of an appropriate weave of fibre glass of a particular type to result in the strength of the manufactured door to be sufficient to render the door effectively bullet proof Also, by changing the material forming the blank/core from a polyurethane to a foam of a phenolic resin foam it has been found possible to enhance the fire resistance properties of the product so that it will a) resist an oxyacetylene flame for a considerable length of time and b) does not give off any smoke or harmful oil fumes so that in the case of, for example, where in the case of a fire the production of additional oil fumes would not be acceptable.
Another feature of the proposals of the present invention is that the door frame may be formed from fibreglass pultrusions, which latter may be regarded effectively as extruded versions of the glass fibre material. This variation adds to the level of security and in the ease of fire, it also improves the fire resistance.
Other frames such as steel and wood can be used but impart varying performance levels.
The proposals of the present invention enables variation of the width of a door leaf within reason during the moulding stage by putting inserts in the mould, even though it is primarily intended for the doors to be moulded in a very few standard sizes.
The frame is designed to be machined if required to allow it to be trimmed or added to with add on pieces. Therefore, unlike the instances of PVC or timber where a solid fixed sized frame is made to fit the hole in the wall and then the door is made to fit the size created by the hole dimensions less the thickness of the frame of the Applicant's proposal works the other way round: This situation enables the production of standard sized doors followed by adjustment of the frame size to fit the hole in the wall by either adding extension pieces to the frames or by cutting the frames down, and in doing so allows us to accommodate the majority of door sizes available in the UK.
A further important advantage arising from the methods discussed herein is that where standard sized doors are fitted to a number of properties in which all the doors are of a fixed and accurate size is that in the event of a door being damaged or needing to be replaced the replacement could be available from a stock thereof.
The door is not coloured through the skin although it can be if required. Some competitors claim this feature as a selling feature. It produces production delays however as the colour of the door needs to be known before starting manufacture.
This therefore upsets the ability to mass produce a standard door.
The colour pigments which are used in fibre glass materials do not generally make for the best surface finish and are prone to weathering at a far more rapid rate than paint finishes. The door is post finished in a primer and paint colour which therefore allows the maximum flexibility to the customer as any colour can be applied at the final operation, and in the event of severe damage the door can be repainted and refinished more easily if painted than if moulded with a colour.

Claims (16)

  1. ---I
    CLAIMS.
    I. A method of forming extended area article such as a door leaf incorporated d within a skin of glass fibre material by forming a blank/core from a rigid form matenal, totally enclosing the blank/core in a layer of fibreglass material, a resin impregnating the fibreglass material to totally encapsulate the blank/core
  2. 2. A method as claimed in claim 1, in which the fibre glass material is a woven fabric and selecting the thickness of the skin of fibre glass according to the physical requirements for the article.
  3. 3. A method as claimed in claim I or 2, and including the step of forming the article in the form of a door construction.
  4. 4. A method as claimed in claim 3, and including the step of profiling the door construction so as to provided at least one relief panel on a surface thereof
  5. 5. A method of producing en extended area article, including the steps of forming/profiling a blank/core of shape and size of a required article, encapsulating the thus form blank/core within a layer of glass fibre material such that the blank/core is totally enclosed within the glass fibre,, introducing the encapsulated blank/core into an appropriately shaped and profiled enclosing mould, and injecting a resin into the mould such that the resin flows through the glass fibre enabling the resin to cure to form a continuous outer skin to the blank/core,
  6. 6. A method as claimed in claim 5 and including the step of forming the blanklcore from from a foamed closed rigid cell foam.
  7. 7. A method as claimed in claim 5 or 6, and in which the blanklcore is in the form of a pack/stack of glass fibre material comprising a plurality of layers of of glass fibre material,
  8. 8. A method as claimed in any one of claims 5 to 7, in which the glass fibre material is in a woven fabric form.
  9. 9. A method as claimed in any one of claim 8, in which the weave of the glass fibre is chosen according to an intended function of the article.
  10. 10. A method as claimed in any one of the preceding claims in which the blank/core is formed from a polyurethane foam..
  11. 11. A method as claimed in any one of claims 5 to 10, in which the blank/core is formed from a phenol resin foam.
  12. 12. A method as claimed in any one of the preceding claims 5 to 11, and including the step of decoratively profiling the blank/core in such manner as to form of a relief in the article.
  13. 13. A method as claimed in any one of the preceding claims 5 to 12, and including the step of forming the blank/core in the form of a door.
  14. 14. A method as claimed in any one of the preceding claims, and including the step of forming the blank/core from fibreglass pultrusions.
  15. 15. A method of forming an article substantially as herein before described with reference to the accompanying drawing.
  16. 16. A door when formed the method as claimed in any one of the preceding claims. I to 10.
GB0807073A 2007-04-20 2008-04-18 Methods of manufacturing a glass fibre door leaf Withdrawn GB2448611A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB0707638.3A GB0707638D0 (en) 2007-04-20 2007-04-20 Methods of manufacture of extended area articles

Publications (2)

Publication Number Publication Date
GB0807073D0 GB0807073D0 (en) 2008-05-21
GB2448611A true GB2448611A (en) 2008-10-22

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GBGB0707638.3A Ceased GB0707638D0 (en) 2007-04-20 2007-04-20 Methods of manufacture of extended area articles
GB0807073A Withdrawn GB2448611A (en) 2007-04-20 2008-04-18 Methods of manufacturing a glass fibre door leaf

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GBGB0707638.3A Ceased GB0707638D0 (en) 2007-04-20 2007-04-20 Methods of manufacture of extended area articles

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Cited By (2)

* Cited by examiner, † Cited by third party
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US20170066167A1 (en) * 2014-02-20 2017-03-09 Basf Se Method for producing a composite component
CN111372765A (en) * 2019-08-09 2020-07-03 世联株式会社 Skin material

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Publication number Priority date Publication date Assignee Title
US20170066167A1 (en) * 2014-02-20 2017-03-09 Basf Se Method for producing a composite component
US12049031B2 (en) * 2014-02-20 2024-07-30 Basf Se Method for producing a composite component
CN111372765A (en) * 2019-08-09 2020-07-03 世联株式会社 Skin material
CN111372765B (en) * 2019-08-09 2021-01-01 世联株式会社 Skin material
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GB0707638D0 (en) 2007-05-30

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