IE78842B1

IE78842B1 - A method of manufacturers of a swing door

Info

Publication number: IE78842B1
Application number: IE960424A
Authority: IE
Inventors: Alphonsus O'mara
Original assignee: Wen Plast Res & Dev
Priority date: 1995-06-07
Filing date: 1996-06-07
Publication date: 1998-03-11
Also published as: IE960424A1

Abstract

A method for the manufacture of a door comprising a variety of steps including providing a first and second mould which are identical to each other; coating the surface of each mould with a gelcoat, a plurality of layers of polyester and a pluraliity of layers of glass fibre. A filler core layer is provided in one of the moulds and one mould is placed on top of the other in mirror image relationship to form a combination mould and subjecting the combination mould to a pressure of between 68.9kPa-206.8kPa. Subsequently, the thus formed door is removed from the combination mould.

Description

- 1 REF: S-DOOR PPA895 A METHOD OF MANUFACTURE OF A SWING DOOR f 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 - 2 7S842 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 ; (l) 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 mould; (q) placing the combination mould in a press at between 68.9kPa-206.8kPa (10-30psi); 5 (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 17°C and 22°C, preferably 20°C.

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 ί 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 17°C and 22°C, preferably 20°C.

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

CLAIMS :

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 V 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 ; (l) 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 mould; (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 17°C and 22°C, preferably ' 20°C. 5 t

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 10 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 15 to and as illustrated in the accompanying drawings. 1/2