MXPA00003412A - Compression molded, inserted thermoset door light frames, plant-on moldings, and decorative panels - Google Patents

Abstract

Door assemblies contain compression molded skins (1, 4) and separately manufactured door light frames, panels, and/or plant-on molding (10) comprised of a thermoset material wherein the separately molded members display substantially the same stainability, gloss, texture, etc., as the compression molded skins (1, 4), and are further strippable without damage to the member. The non-integral door elements may be adhesively bonded to the surface onto which they are affixed.

Description

DOOR LIGHT FRAMES INSERTED, MOLDED BY COMPRESSION, MOLDED PLANT PIECES, AND DECORATION RANKS 1 sft TECHNICAL FIELD The present invention is directed to removable, insertable or adherable door light panels, plant molded parts, and decoration panels, which are durable, match the ink color applied to the exterior door or light frame where they are mounted, and avoid significant degradation when the ink and top coat are peeled off with aggressive finish release agents such as those based on methylene chloride.

PREVIOUS TECHNIQUE Door lights are windows mounted on an exterior door or light frame. Door light assemblies or cassettes generally consist of internal and external molded peripheral frame members, which are the door light frames, both secured together with fasteners that surround the central panels between the frames of glass, plastic or other material. The door light frames are fastened from opposite sides to the door or light frame, in particular to allow differences in the thickness of the doors to which they are to be applied. Decorative panels are generally made analogous to door light frame assemblies with a solid panel replaced by transparent or translucent panels such as those that can be made of glass. The panel can be integral to the peripheral frame or inserted as desired, as predetermined by the process used in the manufacture of frame and central panel. The molded parts of the plant are single peripheral frame members secured to the outer door or side lamp on which they are mounted, The fastener may involve screws or mounting members with integral projections to the frame member. Door light frames, parts molded plant, and decorative panel designs are known in the prior art as illustrated in McConnell's US Patents 4,523,408 and 4,839,989, and Jouanny's French Patent 2328095. In general, door light frames, molding parts of plant, and decorative panels are typically manufactured from steel formed by rolling and / or baking in press, stamping; injection molded polystyrene, polyvinyl chloride (PVC) or thermoplastic reinforced with glass fiber; molded polyurethane foam; A) Yes as extruded and assembled thermoplastic, such as PVC, > 8 & tiií¿ 3 & amp; ': ¿&&M? Ski. , JSaS8ajfe ^ s coextruded laminates of styrene-anhydride aleico PVC (SMA PVC); or wood configures a. The operation and the aesthetic properties of the door light frames, molded floor parts, and decorative panels with relation to the door in which they are mounted are generally determined by the training processes and the materials used, the doors and frames of light towards which the door light frames, the molded pieces of floor, and the decorative panels inserted are typically made of wood, steel, polyvinyl chloride, composite of glass fiber-reinforced sheet molded part, and thermosettable phenolics filled with wood fibers. It is notorious that in the industry of With 15 doors and light frames, a manufacturer's door lights can be used on lw doors and frames manufactured by a second manufacturer. The inking of the exterior doors and the light frames to copy the color or wood grain are want by many customers. Discerning the object of the customers when the inking of the door light frames, the molded floor parts, and the decorative panels do not coincide in darkness, color, or grain texture of the door or light frame towards which assemble the door light cassette. Numerous Problems are common when inking doors, door light frames, rnold parts? # <; Ja $ í plant, and decorative panels. , &g * Doors and steel light frame, light frames; of door, molded floor pieces and decorative panels are generally not acceptable as imitations of inked wooden doors and light frames, even if they are textured to simulate wood, These doors are usually painted, not inked. PVC doors and light frames, door light frames, molded floor pieces and decorative panels are also not typically inked; dark colors allow greater heating of the door surface during direct exposure to the sun. It is typical for PVC to curl and twist as the surface temperature increases to more than about 85 ° C. For reference, the airspace temperature between the glass storm door and a door can reach 95 aC at least once a year in most of the US regions. In addition, ink layers on thermoplastics can experience witness lines caused by significant expansion and contraction due to the relatively high coefficient of linear thermal expansion of PVC, recent modifications to thermoplastics, such as additions of fiberglass reinforcements, and microcellular foam, either PVC or other thermoplastics, eg. , aaü-Ionitrile-butadiene-styrene (ABS), reduce linear thermal expansion and improve thermal resistance, thus mitigating, but not eliminating, distortion and testimony expressions, however, the resulting products when inked yet do not match the thermosetting doors molded by compression. Reinforced PVC and microcellular foam doors are not commercially available. Stainless steel doors and light frames are known in the prior art. These products consist of steel door and light frame assemblies coated with a plastisol coating. thin PVC, The PVC surface can be textured to imitate wood grain. No door light frames, molded floor parts or decorative panels are currently manufactured to duplicate this door surface or light frame. But, even if there were, the detachment of the top layer and ink from these PVC surfaces with aggressive solvents that are typically used, irreparably damage the PVC surface with plastisol. Doors and wooden light frames, -, door light frames, 3-piece molded parts, and decorative panels "have been aesthetically acceptable, especially when using wood veneers, however, these products are notoriously difficult to maintain due to the expansion and contraction with humidity as well as degradation of the wood substrate by ultraviolet light due to sun exposure, variation of color and texture of the wood due to different species, frequency use of randomly joining wood cuts, as well as as the natural variation within species and within individual tables makes the coincidence exceptionally difficult.The detachment of the upper layer and inking of these doors is a very difficult and frequently unsatisfactory process that may include the substantial use of bleaching compounds. Decorative panels are often made integral to the door or light frame assembly and therefore, the complete set or door or light frame must be replaced when a single panel is damaged. The door and light frame assemblies have been made by compression molding of sheet molding compound or phenolic based resin resins with wood fiber. These doors are intended for inking and additionally characteristic texture for • ib simulate wood grain, examples include door assemblies shown ^ - «in US Patent, No, 4,550,540 and in the provisional EU application, A. No, Series 60 / 010,838, Examples of materials necessary for similar wood grain are shown in US Pat. No. 5,537,789. All of these are incorporated herein by reference, the compression molded door frames and light frames with integrally molded thermoset decorative panels and integrally molded thermosetting door light frames such as those described in US Pat. No. 4,720,951, allow the production of products with improved static, durability and matching inking capacity. In addition, the upper layer and the inking are more easily removed from these products by peeling. However, when the integrally molded glass unit fails, the complete light door or frame assembly must be replaced at considerable cost. The cost of storage and / or driving time for product delivery required to maintain an equivalent number of units of material, as opposed to using insertable door light frames, molded pieces of floor and decorative panels is increased unacceptably. i¡i¡i ^ m ~ &. ^. jatmeMs- In addition, the manufacture and shipment of door assemblies and light frames with decorative panels integrally molded is very difficult. The surface area of inference of the light face of the door or light frame is small, requiring extra strength in the thermosetting material to prevent grinding, or requiring a tray formed to protect the raised surfaces. Both of these alternatives add substantial manufacturing costs. Due to these reasons, door light frames, molded floor parts and decorative panels that can be subsequently inserted into the door or light frame have been accepted by the market as the preferred approach to reduce manufacturing and inventory costs. as well as for ease of handling, the molded door light frames, the molded floor parts, and the decorative panels that provide peripheral skins capable of inking have been prepared using molded polyurethane foam with densities of 190-400 kg / m3, However, to accept inking, a primer coating containing relatively high percentages by weight of pigments and inorganic solids must first be applied. Door assemblies that use exterior surfaces of solid molded polyurethane or Polyurethane laminates have not been economical and have not found commercial success. The lower light frame panel assemblies of solid molded polyurethane to which door light frames and decorative panels have been inserted have been commercially introduced and subsequently removed, replaced by compression molded thermoplastic light frame assemblies. Embedded frames of molded polyurethane foam, molded plant parts, and primed decorative panels should closely approximate the inking capacity of compression molded doors. Coincidence is generally not yet acceptable to discern by customers, however, at polyurethane foam densities that are economically feasible (approximately 190-400 kg / cm3), these frames, molded plant parts, and decOrative panels are still very Fragile during shipping and installation, They are susceptible to thread detachment by screws used to assemble them, and are subjected to easy abrasion of the primer coating. Unless polyurethanes are prepared from aliphatic disocyanates, door lights and other products that are exposed to the sun due to weathering or wear ? Ür.

Inking and top coating can degrade quickly. Door light frames, molded floor parts, and decorative panels with a scale density of approximately 300-1200 kg / m3 that are durable and capable of inking have been prepared using low pressure injection molding of reinforced thermoplastics The resulting products are more porous than the skins manufactured by compression molding. As a consequence, applying equivalent amounts of ink to the light door or frame skin or March door light surfaces results in a darker inking on the door light frame. Clients who discern find that difference unacceptable. Significant effort and experience must be spent to reduce the effects of porosity during the inking of frames, molded pieces of plant, and decorative panels produced by injection molding at low pressure. These include impregnation of the aesthetic surfaces of the decorative panels or door light frames with a volatile thinner such as a paint thinner, priming the aesthetic surfaces of the door light frames or decorative panels with a sealer, or diluting the ink with a compatible solvent. All techniques require a - Increased elapsed time to finish the door surface and the njun or door light frame. Therefore, there is an economic penalty generally unacceptable to the user. In addition, exposures in excess of 20 minutes to aggressive paint scrubbers, such as ethylene chloride strippers, soften the aesthetic surface material and remove the primers. Therefore, there is a need for materials and processes that produce insertable door light frames, molded floor parts, and durable decorative panels that can be economically inked to match the color and aesthetics of the compression molded thermoset door surfaces. where they are installed, materials and processes should produce door light frames, molded pieces of plant, and decorative panels that allow the simple detachment of the top layer and ink without damaging the aesthetic surface, and that are capable of supporting the temperatures give use without distortion. It would also be desirable to produce puetta light frames, molded floor pieces, and decorative panels that can be applied to door frames without requiring complicated fasteners, and on panels, without requiring cutting holes in the door, '"» ,, a. WKe? &' F-- -s? Sr * - ~ «usatiÁ -_.

EXHIBITION OF THE INVENTION The present invention? It is aimed at removable door light framesnsertables, molded pieces of plant, and decorative panels manufactured by compression molding a curable material towards a resin material without foam, thermosetting. These door lights, molded floor parts, and decorative panels are manufactured separately from the skin or door slab, and may be referred to herein as "non-integral door elements". The curable material is composed of organic resins that are prepolymerized or that are further polymerized during molding, reinforcing fibers, inorganic or organic fillers, and such additives typically used to aid the molding or add properties such as fire retardancy or resistance to fungal degradation, which are cured during or after the molding process towards a thermoset material, resistant to solvent. Door light frames, molded floor parts, and decorative panels have an exterior aesthetic surface and an interior surface. The outer surface may include textured patterns analogous to the skin or compression molded thermoset door surface to be twinned, these , j ** patterns generally consisting of level portions or depressions predetermined by the texture of the molding tool texture. These depressions are generated on tool surfaces by etching or other means to produce a pattern that simulates the wood grain in order to improve the aesthetic appearance resemblance to the wood grain as well as to assist mechanical entrapment of pigment during the process of inked The primary object of the present invention is to provide door light frames, floor molding pieces, and durable, insertable decorative panels that can be inexpensively inked to match the color and aesthetics of the thermoset door surfaces molded by pressure on which they are installed. Other objects and advantages of the invention will become apparent after a review of the description of the preferred embodiments and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a front elevation view of a door light frame as a component of a door light assembly, Figure 2 is a cross-sectional view * # * ' taken along axis 2-2 of Figure 1; The one-piece front elevation Figure 4 is a cross-sectional view taken along the axis 4-4 of Figure 3, showing the planked piece. Figure 5 is seen in front elevation of a decorative panel; and Figure 6 is a cross-sectional view taken along the axis 6-6 of Figure 5, showing the two decorative panels as components in a decorative panel assembly, BEST MODE FOR CARRYING OUT THE INVENTION Example 1 The present invention will now be described in detail with reference to the accompanying drawings. In this example, the door light frame 1 is composed of molding compound taken from the following families of compounds: molding compound by volume (or mass); compound of kneading molding; an injection molding compound known as AMC, thick molding compound; a sheet molding compound, both varieties, chemically thickened and physically thickened, more preferably the compounds "A" - "-Ai-r? - ^, 1 molded in epoxy volume, vinyl ester, phenolic, based on dicyclopentadiene and polyester and sheet, and more preferably, sheet molding compound unsaturated polyester This is a material comprised of fibrous glass of cut glass S of 5 to 72 weight percent fiberglass reinforcing, preferably 17-25 weight percent, and most preferably 19-22 weight percent 2-3 mm long; inert fillers; mold releasers; and other additives in the molding resin. Other reinforcements can be replaced by fibrous glass such as wood and lignocellulose fibers, ara-fiber fibers, carbon fibers, or mineral reinforcements such as mica. Fillers may include wood, sawdust and exclelsior as well as inorganic fillers such as calcium carbonate. Unsaturated polyester polymers blended with vinyl monomers such as styrene are molding resins that can be cured under heat and pressure to form thermoset compression molded door frames. Suitable molding compounds are described in U.S. Patent No. 3,772,241 to Kroekel and in U.S. Pat. No. 3,8983,612 to Pratt et al, which are incorporated herein by reference, Curable materials that produce foam materials are not suitable in the present invention, ^^^^^^^^^^^^^^^^^^^^^^^^ i ^^^ te ^^^^^^^^^^^^^^^^^^^^ ^^ i ^^^^ - 1 < Preferred sheet molding compositions are prepared by mixing a resin mixture with an additive portion, the additive portion containing conventional SMC additives such as thickeners, fillers, pigments, etc., and the resin portion containing curajy resin., ©, Catalyst and other components, The relative amounts of the resin portion and the additive portion can be varied to be appropriate to the particular application, but is usually around 18: 1 by weight. The resin portion preferably contains a ratio of 60:40 of an alkyd modified propylene glycol maleate resin, thinned with styrene, and thin impact polystyrene thinned with styrene. Both resins are commercially available, for example from Cook Composi es and Polymer, Kansas City, Missouri. The resin portion also contains, in relation to 100 partsa of the above resins, 4.0 parts of polyvinyl acetate; 1.56 parts of t-butoxiperoxybenzoate catalyst; 1.56 parts of calcium stearate; and 2.08 parts of microfine polyethylene, available as FN 510 from Quantum Chemical, Cincinnati, Ohio; 0.31 parts of PEP100, an organocobalt compound on calcium carbonate support available from Air Products ^ Allentown, .

Pennsylvania; and 197.60 parts of calcium carbonate filler available from Huber, Norcross, Georgia, as Huber W-4 calcium carbonate. To the total mixture, cut glass-S, nol length of 2.54 centimeters, is added in an amount of approximately 22 weight percent. This door light frame has a thickness between 1.25 mm and 4 mm, preferably 1.25-2.5 mm in the wall and 2-0-2.6 mm in the screw protuberances, - if present. The density of the product varies between approximately 1500-2350 kg / m3, as deterd mainly by the amount of material loaded in the press and the pressure of the press. The compression pressure may vary from 1000 to 15,000 kPa, preferably from 2,500 to 5,100 kPa at temperatures of 150eC to 180aC. The aesthetic, exterior surface of the door light frame is essentially free of reinforcing fibers by a predeterd depth of 0.10 mm. This surface rich in resin helps to accept the ink. The non-textured door light frame can effectively have fibers on the surface, and requires a decoration surface applied either in situ during molding or during a secondary decoration operation to make an aesthetically acceptable door light frame in a manner that the fibers do not ..,. You can see the ink through the ink. Referring to FIGS. 1 and 2, the door light March has an exterior aesthetic surface 4 and an interior surface 10. In a set of door light, a pair of opposed compression molded door frames surround a central panel comprised of one or a plurality of the following sheets 3 of glass, decorative cut glass 8, knocker 7, and sealant 6 Also, not shown for purposes of clarity are well-known articles such as high temperature plastic inserts, spacers, dissectors, and coatings and films designed to reduce heat transmission. The inner surface of the outer door light frame may have a sealant 5 impervious to water, adhesive, fixed between the frame and the outer surface of the central panel. Essentially the same material can be used to form door skins molded by compression. The door skin assembly or compression molded light frame is prepared with a hole to receive the insertable door light assembly. The inner surface of the March door light outside the set adjacent to the door skin surface or light frame can have a sealant 9 impermeable to j J r- ia A. ' - to £ afcM water fixed between the frame and the outer surface of the compression molded door assembly. The assembly to the door or light frame assembly by any of the various fastening methods including the following: press adjustment projections, intersubject toothed fasteners, and more typically screws. In this example, the screws 2 are applied from the outermost side of the interior door light frame to screw protrusions integrally molded in the door light march. Figures 3 and 4 illustrate a plant molded part consisting of the frame 17 and the pressure fasteners 18.

Example 2 In this example, the decorative panel 20 (Figures 5, 6) is composed mainly of resin systems based on phenolic formaldehyde and wood fiber of less than 19 um maximum cross section and greater than 1.25 mm mum length, preferably 3 mm to 6 mm, Materials that can be used in this example on weather-exposed faces are provided in PCT Patent Application Serial No. PCT / US97 / 14290 and US Application Serial No. 08 / 791,023, incorporated herein by reference. asx Í - 20 - The phenol-formaldehyde system can be selected from the resin families that contain the phenol and forpialdehyde lobes; resins of phenol-formaldehyde? -mela; resoles phenol-formaldehyde with separate melamine resin coating; novolaks of phenol-formaldehyde; or phenol-for-aldehyde novolaks with another silane, siloxane, polysiloxane, or high molecular weight polyurethane coatings; preferably the resoles with melamma coatings or novolacs with siloxane coatings; more preferably novolaks with a plurality of pre-press siloxane coatings including intimately mixed siloxane coatings for transmission control moisture vapor and water-based siloxane coatings separated for water repulsion. A peripheral frame of decorative panel exposed only to interior conditions 12 may employ a urea-formaldehyde resin, urea-formaldehyde fortified with melamma, or one of melamine-urea. The interior areas 14 and 16 of the panel are composed of the same materials as the outer and inner peripheries 12 and 15, respectively. The panel is fixed through screw 13. Seal packing 17 is sealed around the outside of the panel. ^^ vkSe &M In the jjgja mode the interior decorative panel 15, it is preferable to use phenol-formaldehyde novolacs applied to the lignocellulosic fiber material, more preferably wood fiber, ba or steam pressure of 350-2370 Kpa, more preferably 920-1750 Kpa- Y more preferably 1400-1700 Kpa, in a single disk or double disk refiner. Green hardwood chips are the preferred source of lignocellulose; however, dry wood, waste of urban wood such as pallets, and lignocellulosic agricultural materials can be used. The resin system from which interior decorative panels are manufactured is not as sensitive to the weather as exterior aesthetic surfaces. The base of the material is predetermined by the density of the molded product, the temperature at which the fiber is exposed, and the duration of that exposure. The density is predetermined by the amount of material loaded in the press and the required compression pressure. The temperature is predetermined by the steam pressure used. In this mode, the preferred densities vary from 1.02 - 2.08 kg / cm3. The compression pressure may vary from 1000 to 15,000 Kpa, preferably 2,500 to 5,100 Kpa. For exterior weathering capacity, resin * it should constitute 4-24 percent of the weight of kiln-dried base of the material, preferably 10-15 percent by weight. The fibers and fillers should constitute 70-90 percent by weight, with the rest of the formulation comprised of additions of processing aids and other properties. For decorative panels used on the interior side of the assembly, the resin content may vary from 1-24 weight percent of the kiln-dried base weight of the total material, preferably 4-8 weight percent. Referring again to Figures 5 and 6, the decorative panel walls 16 and 14 vary from 1.75 mm to 22.5 mm thick. In the present embodiment, the wall thickness is nominally 3 mm while the screw protrusion walls 21, if used, are nominally 5 mm, It is preferred to match the decorative panels with the door skins in terms of resin system and density.

Example 3 To achieve the light-colored inks preferred by some customers, it may be necessary to use a light-colored decorative surface, such as a paint primer, on the darker colored decorative panels. These darker panels can be created by the material methods outlined in Example 2, wherein the density scale is 1.02 - 2.08 kg / cm3, more preferably 1.66-2.08 kg / cm3, and vapor pressure of 350-2370 Kpa, more preferably 1700-2300 Kpa, more preferably 1800-2200 Kpa in a single disk or double disk refiner. The phenolic novolak resin content may vary from 1-24 weight percent with 10-15 weight percent preferred for panels exposed to outdoor weathering of the house and 4-8 weight percent preferred for panels exposed to interior conditions. A decorative surface can be created using films, plies impregnated with resin, wood chips, laminates or paint retention primers. Preference is given to paint-retaining primers that can be developed from relatively high molecular weight polyurethane polymers, preferably thermoplastic urethane coatings in excess of about 50,000 weight average molecular weight.; polysaccharide resins with a number average molecular weight of 100,000-300,000, more preferably 100,000 to 200,000; Acrylic-urethane hybrid polymers; Polymeric styrene-acrylic resins; chloride and vinylidene coatings, ethylene-vinyl chloride coatings. preferably for-hardened ll from an emulsion of 20-40 percent < && 43% weight of alkylalkoxysiloxane solids; such as Wacker1® 43A, 0.1-5 weight percent 50% solids siloxane solids such as Sealer Science ™ l & Plus1® or Wacker 1306; -50 weight percent acrylic resin of 43% solids, such as BF Goodrich "Carboset", 0.1-10 weight percent of a resin with lower glass transition temperature than the siloxane and acrylic resins such as ethylene vinyl chloride resin with glass transition temperature between 11 and 35aC, such as Air Producís *** Airflex1411 4514, as well as solvents, adjuvants, fungicide, anti-mildew agents, fillers and additional extenders that can be added up to 49 8 percent by weight; waxes; as well as combinations thereof. In this preferred embodiment, polysaccharide resins with number average molecular weights of 100,000-300,000, more preferably 100,000 to 200,000 are used with styrene-acrylic polymer resins; vinylidene chloride coatings; ethylene-vinyl chloride coatings, preferably formulated from an emulsion of 20-40 weight percent of alkylalkoxysiloxane of 43% solids; such as Wack? rMR 43A, 0.1-5 percent in -t &M & fats »weight of 50% solids siloxane polymer; such as Sealer Science1 * Síloxane Plus ** or Wacker 1306; 30-50 weight percent acrylic resin 43% solids, such as BF Goodrich ™ Carboset * 8; and 0.1-10 weight percent of a resin with lower glass transition temperature than siloxane and acrylic resins such as ethylene vinyl chloride resin with glass transition temperature between 11 and 35 aC, for example Air Producis "" Airflex "" 4514, as well as solvents, adjuvants, fungicide, mildew agent, fillers and additional extenders which may be added up to 49.8 weight percent; waxes; as well as combinations thereof. In this preferred embodiment, polysaccharide resins with a number average molecular weight of 100,000-300,000, more preferably 100,000 to 200,000 are used with styrene-acrylic polymer resins, this primer enhances the aesthetic benefits by allowing relatively uniform dispersion of pigments from lighter color on the surface while limiting the differential absorption to the various areas of different inherent porosity on the surface of a decorative panel formed from the materials delineated in Examples 2 or 3. This results in a wider scale of colors of ink available for difficult customers, but reduces the benefits economic and durability use non-primer surfaces. In this manner, the present invention pertains to a door light frame or decorative panel comprised of opposite internal and external skirt members, these members being generally formed from the same material, and particularising approximately the same surface texture as the door skin. molded or light frame skin to which the door light march is to be inserted, these components manufactured from thermosetting molding resins or molding resins that become thermoset during the molding process or through a subsequent treatment of the molding. The door light frames or decorative panels are preferably made from a thermosetting molding resin which is a molding compound of glass fiber reinforced sheet and a thermosetting molding resin which is a phenolic compound filled with lignocellulosic fiber. The external molded members are preferably suitable for prolonged exposure to the weather. To this end, for example, the external molded door light frame may consist of a thermosetting molding resin which is phenolic composite filled with lignocellulosic fiber containing or coated with ^ Ll ^^ - 2 ^ one or more agents that provide hydrophobicity. Preferably, the ionic compound filled with ligonocellulosic fiber is primarily a phenol-formaldehyde novolac-and the hydrophobicizing agent contains organosiloxane and / or organosilane resins bearing reactive functional groups. Preferably, the hydrophobicity-providing agents contain organosiloxane or silane resins containing reactive functional groups. A linear amino-functional siloxane can be intimately mixed with the lignocellulosic fiber in a refiner, or the silane can be applied to the mat surface of ligonocellulosic fiber prior to molding. The present invention further pertains to a door light frame or decorative panel comprised of opposite inner and outer molded members, these members being formed with approximately the same surface texture as the molded door skin or the light skin of March. where the door light frame or decorative panel is to be inserted, where the door light frame or decorative panel demonstrates color of inking, uniformity of color, and luster, as well as appearance of texture that closely matches the color of Inking, uniformity of color, and luster as well as texture appearance of door skin or light frame skin where the door light frame or decorative panel is to be inserted, whether door light frame or decorative panel is with The use of materials such as ink and top coating applied to the door light frame or decorative panel is removable without visible damage to the eyes without help using detachments. Paint sources, particularly those employing powerful solvents such as methylene chloride as a primary ingredient. The door light frames, decorative panels, or plant molding members of the present invention are preferably made from compounds based on thermosetting molding reams or molding resins that remain thermoset during the molding process or through a subsequent molding treatment, which are molded under pressure from 1,000 to 15,000 Kpa to a predetermined thickness of 1 25 to 19 mm, the molding operation occurring at temperatures of 121aC-218aC, in a preferred, the light frame of door, decorative panel, or plant molding member is molded from molded sheet molding compound at 2,500 to 5,100 Kpa at molding temperatures of 150aC-180aC In a second preferred embodiment, the door light frame, decorative panel or member of molding in plant is molded from a composition that - 29, "> • * •" Contains 1-24 wt.% phenol formaldehyde novolac mixed with wood fiber ^ molded under pressure ranging from 2,500 to 51,000 SÜi at molding temperatures of 200cC-218aC. These molding compositions are referred to herein as "novolac / partially digested wood fiber compositions". In a further embodiment, the door light frame, the decorative panel, or the plant molding member is appropriate during appropriate exterior exposure, and is made from compounds based on thermosetting molding resins or molding resins that have been thermosetting during the molding process or through a subsequent molding treatment, these compounds being of approximately the same material as the door skin or the skin or light frame surface where they are inserted, the composite having been impregnated with coatings that they restrict moisture or transmission of moisture vapor to the member, the member being molded under pressure of 1,000 to 15,000 Kpa to a predetermined thickness of 1.25 to 19 mm at temperatures of 121aC-218aC. More preferably, the door light frame, decorative panel, or plant molding member is produced from a compound containing 1-24% by weight of phenol formaldehyde novolac intimately mixed with wood fiber applied to the - 3p - refining process of fi§fa, mixed with the fiber before the formation of «mat, or impregnated in the mat before pressing, the compound having alkylalkoxy-siloxane intimately mixed with the fibers that are part of the compound during the refining, mixing in the fiber before the matting of the composite impregnated into the composite mat prior to pressing, or applied to the composite mat or tool surface in contact with the composite mat as part of the press forming operation, and The surface layer of the composite mat impregnated with the silane compounds, the compound molded under pressure from 2,500 to 5,100 Kpa at molding temperatures of 200sC-218aC. In a still further embodiment, a molded piece of plant is comprised of a molded member, this member being formed of approximately the same material and particularizing approximately the same surface texture as the skin or molded door surface or light frame skin towards the that the molded piece of plant is to be fixed, these members made with thermosetting molding reams or molding resins which are thermoset during the molding process or through a subsequent molding treatment, preferably the molding compound of &;. ' fiberglass reinforced sheet or phenolic compound filled with fiber. As with other embodiments, these exterior plant molding pieces are suitable for prolonged exposure to weathering, and more preferably comprise phenolic compound filled with lignocellulosic fiber with an agent that provides hydrophobicity. The agent that provides hydrophobicity preferably comprises organosiloxane and / or organosilane resins which contain reactive functional groups. More preferably, the molded piece of plant is formed with approximately the same surface texture as the molded door skin or skin or light frame skin in which the molded piece of plant is placed or inserted, and in addition demonstrates inked color, uniformity of color, and luster, as well as texture appearance that closely matches the color of inking, uniformity of color, and luster as well as texture appearance of door skin or light frame skin , to which it is placed or insert the molded piece of plant. These molded pieces of plant preferably can be detached without visible visible damage without help using paint strippers, even when the release agents using methylene chloride are used as a primary ingredient.

The present invention also pertains to door assemblies which comprise at least one skin or molded surface and at least one separately fabricated door light frame, decorative panel, or plant molded part of the present invention which it is capable of being inked with the same or substantially the same ink as the door panels themselves, to provide a march of inked door light or another component described above which has substantially the same color and depth of color as the door itself. door skin. In other words, the separately manufactured component will be inked in approximately the same manner as the door skin itself. It is believed that door light frames, floor molding pieces, and decorative panels have not previously been produced from the thermosetting resin compositions of the present invention due to the difficulties expected in molding articles such as those described in US Patents TO. 4,523,408 and 4,839,989. however, it has surprisingly been found that even relatively complex molded parts can be produced by the present process. Additionally, it has been surprisingly discovered that door lights and molded parts of plant and panels can be produced without the need for physical fixation methods, these elements being mounted towards the door by means of an adhesive film that can also serve as a sealer in the case of door lights. In the case of decorative panels and the like, the use of film adhesives allows the assembly of panels and the like without first forming a hole in the door to receive opposingly matched elements inserted as described in the prior art. This construction allows a stronger and more resistant to the weather. In an alternative embodiment, a door light frame member can simply be molded and designed for adhesion by means of adhesive, while the matching member can be designed for conventional mounting by screws, deformable inserts, etc. In such case, if the glass in the break door light, can be easily replaced by removing the mounted member in a conventional manner. For example, conventional door slabs with ten panels were measured for thermal deflection and torsion. The door slab that has the panels mounted with adhesive tape exhibited approximately the same total thermal deflection with greater deflection in the upper part of the door * lesser in the bottom. The torsional stiffness of the panel door applied with adhesive was surprising, however, exhibiting almost three times the torsional stiffness of a similar door having recesses and panels mounted within the recesses by conventional clamping methods (screw). Many adhesive tapes are appropriate, and many are commercially available. A preferred tape, however, is VHB 4930 tape manufactured by the 3M Company. It is generally necessary to wash the areas on the door slab that will bond to the panels with an aggressive solvent to remove waxes, mold releases, etc. A suitable solvent is Tape Primer 94 available from 3M. Isopropanol, methyl ethyl ketone and similar solvents are also suitable. The adhesively bonded elements showed no sign of loss of weathering, or exposure to mineral spirits, Glass Plus ™ Window Cleaner, Fast-n Easy * ® Acetone Ammonia Cleaner, 3M Safest Stripper Brand Release Compound, or Zar * ® methylene chloride base paint and varnish remover. In the claims, the term "external" as it refers to surfaces, is the surface of the door skin, light frame surface, etc., to which '. * the door light frame, molded piece of floor or floor panel will be fixed, as opposed to an "interior" surface that is internal to the door, etc. By the term "exterior" is meant a surface that is exposed to the elements in a house or building, as opposed to an "interior" surface that is oriented to the interior of the building. $ & tgSWai ^

Claims (2)

1. - A door element that can be inked, removable, not integral, comprising a thermoformable compression piece molded without foam, cured, 2 - The non-integral door element according to claim 1, wherein the molded part cured thermosetting compression is prepared from a thermosetting composition selected from the group consisting of sheet molding compound, bulk molding compound, thick molding compound, and novolak / partially digested wood fiber compositions. 3, a door or light frame manufactured with an outer surface molded by compression, and mounted to the outer surface of one or more non-integral, removable door elements, capable of being inked in accordance with claim 1. 4, a door or light frame fabricated with an external surface molded by compression - and mounted to the external surface of one or more of the non-integral, removable door elements, capable of being inked in accordance with claim

2. 5. - The door or compliance light frame a .Tosíais .. > -. . Aa &mstfc & .i '- «», "..» with claim 3, wherein the non-integral door element accepts ink as much as the outside surface of the door or light frame without treatment other than the non-integral door element compared to the treatment received by the outer surface . 6. The door or light frame according to claim 4, wherein the non-integral door element accepts ink to the same degree as the outer surface of the door or light frame without treatment other than the non-integral door element in comparison with the treatment received by the outer surface. 7. The door or light frame according to claim 3, wherein at least one side of a pair of matching sides of a non-integral door element is fixed to the outer surface by means of an adhesive tape. 8. The door or light frame according to claim 4, wherein both sides of a pair of matching sides of a non-integral door element are fixed to the outer surface by means of adhesive tape. 9. The door or light frame according to claim 5, wherein both sides of a pair of matching sides of a non-integral door element is fixed to the outer wall by means of adhesive tape, 1. - The light door or frame according to claim 6, wherein both sides of a. pair of matching sides of a non-integral door element is fixed to the outer surface by means of adhesive tape. 11. A process for the preparation of a door or light frame that has attached thereto a non-integral door element, the non-integral door element comprising a thermosetting compression-molded element, without foam, removable, capable of inking, which accepts ink to the same extent as an exterior surface of the door or light frame to which the non-integral door element is attached, the process comprising rubbing the outer surface of the door or light frame to which the door element will be fixed. non-integral door with an amount of adhesion promotion of one or more organic solvents, and subsequently ligating the non-integral door element to the external surface by "means of an adhesive tape placed between the outer surface and the non-integral door element. 12, - The process according to claim 11, wherein the door element does not ^^^^^^^^^^^^^^^^^^^^^^^^^^^ g ^^^ S ggg ^^^^^^^^^^^^^^ integral comprises two 13 * coincident, one of the sides to be fixed ¿Í | it gives one of two opposite sides of the light door or frame, wherein only one of the two sub-elements is adhesively bonded with the ink adhesive, the second of the two sub-elements fixed to the door or light frame by non-adhesive means, 10 fifteen twenty 25 JÉ- ^ ^ ^ »¿¿¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡¡