WO2002009930A2 - Procede de fabrication d'un panneau composite - Google Patents
Procede de fabrication d'un panneau composite Download PDFInfo
- Publication number
- WO2002009930A2 WO2002009930A2 PCT/IB2001/001308 IB0101308W WO0209930A2 WO 2002009930 A2 WO2002009930 A2 WO 2002009930A2 IB 0101308 W IB0101308 W IB 0101308W WO 0209930 A2 WO0209930 A2 WO 0209930A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- panel
- thermosetting resin
- composition
- edging
- mould
- Prior art date
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 8
- 238000007688 edging Methods 0.000 claims abstract description 85
- 229920005989 resin Polymers 0.000 claims abstract description 71
- 239000011347 resin Substances 0.000 claims abstract description 71
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 61
- 239000000203 mixture Substances 0.000 claims abstract description 52
- 229920005830 Polyurethane Foam Polymers 0.000 claims abstract description 13
- 239000002245 particle Substances 0.000 claims abstract description 13
- 239000011496 polyurethane foam Substances 0.000 claims abstract description 13
- 239000003054 catalyst Substances 0.000 claims abstract description 12
- 239000012779 reinforcing material Substances 0.000 claims abstract description 12
- 239000011256 inorganic filler Substances 0.000 claims abstract description 9
- 229910003475 inorganic filler Inorganic materials 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 34
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims description 8
- 239000011248 coating agent Substances 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 8
- 229920006337 unsaturated polyester resin Polymers 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 5
- 230000001070 adhesive effect Effects 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 239000002023 wood Substances 0.000 claims description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 4
- SLGWESQGEUXWJQ-UHFFFAOYSA-N formaldehyde;phenol Chemical compound O=C.OC1=CC=CC=C1 SLGWESQGEUXWJQ-UHFFFAOYSA-N 0.000 claims description 3
- 229920001568 phenolic resin Polymers 0.000 claims description 3
- 229920003987 resole Polymers 0.000 claims description 3
- 239000000565 sealant Substances 0.000 claims description 3
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 2
- 239000011152 fibreglass Substances 0.000 claims description 2
- 229910052751 metal Inorganic materials 0.000 claims description 2
- 239000002184 metal Substances 0.000 claims description 2
- 239000000049 pigment Substances 0.000 description 4
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 3
- 235000011613 Pinus brutia Nutrition 0.000 description 3
- 241000018646 Pinus brutia Species 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000012978 lignocellulosic material Substances 0.000 description 2
- 239000005445 natural material Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 150000003673 urethanes Chemical class 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- MMEDJBFVJUFIDD-UHFFFAOYSA-N 2-[2-(carboxymethyl)phenyl]acetic acid Chemical compound OC(=O)CC1=CC=CC=C1CC(O)=O MMEDJBFVJUFIDD-UHFFFAOYSA-N 0.000 description 1
- WFUGQJXVXHBTEM-UHFFFAOYSA-N 2-hydroperoxy-2-(2-hydroperoxybutan-2-ylperoxy)butane Chemical compound CCC(C)(OO)OOC(C)(CC)OO WFUGQJXVXHBTEM-UHFFFAOYSA-N 0.000 description 1
- 229910002012 Aerosil® Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 229910002055 micronized silica Inorganic materials 0.000 description 1
- 125000005609 naphthenate group Chemical group 0.000 description 1
- 150000001451 organic peroxides Chemical class 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 229920002379 silicone rubber Polymers 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
- B29D99/00—Subject matter not provided for in other groups of this subclass
- B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/1228—Joining preformed parts by the expanding material
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/18—Filling preformed cavities
-
- 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
- B29C70/003—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties
- B29C70/0035—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised by the matrix material, e.g. material composition or physical properties comprising two or more matrix materials
-
- 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
- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
- B29C70/026—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled 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
- 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
- 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
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
Definitions
- THIS invention relates to a method of making a composite panel from two substantially similar panel skins, and to the composite panel so made.
- a method of making a composite panel from two substantially similar panel skins and an edging, each panel skin being made in a mould including the steps of: (1) forming a first panel skin by:
- thermosetting resin a thermosetting resin
- a catalyst for the thermosetting resin and inorganic filler particles to a surface of a first mould
- thermosetting resin (b) allowing the thermosetting resin to set to form an outer face of the first panel skin; -9-
- step (1)(b) forming a layer of a fibrous reinforcing material wetted with a second composition comprising a thermosetting resin and a catalyst for the thermosetting resin on the product of step (1)(b);
- thermosetting resin in the second composition (3) allowing the thermosetting resin in the second composition to set to form a combination of the first panel skin with the edging attached thereto, and optionally removing the combination from the first mould;
- thermosetting resin (b) allowing the thermosetting resin to set to form an outer face of the second panel skin
- step (c) forming a layer of a fibrous reinforcing material wetted with the second composition on the product of step (4)(b); either
- thermosetting resin in the second composition before the thermosetting resin in the second composition has set, placing an edging all around the edge of the product of step (4)(c);
- thermosetting resin (6) allowing the thermosetting resin to set to form a combination of the second panel skin with the edging attached thereto, and removing the combination from the mould;
- thermosetting resin in the second composition has set, placing the combination of step (3) on the product of step (4)(c) with the edging in contact with the product of step (4)(c);
- thermosetting resin (9) allowing the thermosetting resin to set to form an intermediate panel from the second panel skin and the combination, the intermediate panel including a cavity defined by the first and second panel skins separated by the edging;
- step (10) filling the cavity with a polyurethane foam to form the composite panel.
- the method of the invention preferably includes the additional steps of: between steps (1)(b) and (1 )(c) and/or between steps (4)(b) and (4)(c), applying a layer of a third connecting composition comprising a thermosetting resin and a catalyst for the thermosetting resin to the product of step (1)(b) or the product of step (4)(b);
- steps (6) and (7) removing any excess material from the two combinations so that the two combinations are of substantially similar size and of the desired thickness;
- the edging or edgings do not include one or more holes therethrough, between steps (7) and (11) or between steps (10) and (1 1) forming one or more holes in the edging or edgings to allow access to the cavity in the intermediate panel;
- step (1 1) applying a decorative coating and/or a sealant coating to one or both outer faces of the first and second panel skins of the composite panel.
- Figure 1 is a plan view of a combination of a first panel skin with an edging attached thereto for use in a first aspect of the method of the invention
- Figure 2 is a sectioned side view of the combination of Figure 1 , together with an identical combination
- Figure 3 is a sectioned side view of a composite panel of the invention formed from the combinations of Figure 2
- Figure 4 is a sectioned side view of a combination of a first panel skin with an edging attached thereto for use in a second aspect of the method of the invention
- Figure 5 is a sectioned side view of the combination of Figure 4, together with a second panel skin
- Figure 6 is a sectioned side view of a composite panel of the invention formed from the combination and second panel skin of Figure 5.
- the crux of the invention is a method of making a composite panel from two substantially similar panel skins and an edging or edgings, wherein each panel skin is made in a mould.
- Each mould is preferably made of a silicon rubber. Further, each mould preferably replicates the surface of a natural wood or other natural material, so that the composite panel made using the mould, replicates the appearance of the natural wood or other natural material.
- the first step of the method of the invention is to form a first panel skin in a first mould by applying a layer of a first composition to a surface of the mould.
- the first composition comprises a thermosetting resin, a catalyst for the thermosetting resin, and inorganic filler particles.
- thermosetting resin in the first composition is preferably chosen from the group consisting of isophthalic or orthophthalic unsaturated polyester resins and phenol formaldehyde resole resins.
- thermosetting resins in the first, second and third compositions do not need to be the same thermosetting resin.
- phenol formaldehyde resole resin is J2018L by Borden Chemical Company, typically catalysed at between 6% to 10% with an acid catalyst such Phencat 10.
- thermosetting resin is an unsaturated polyester resin
- an orthophthalic unsaturated polyester resin is used for composite panels intended for interior use
- an isophthalic unsaturated polyester resin preferably a neopentol glycol modified resin
- examples of these resins are those manufactured by Scott Bader including Crystic 272. These resins are preferably pre-accelerated with accelerators such as a cobalt octoate or a naphthenate catalysed with an organic peroxide, such as methyl ethyl ketone peroxide.
- the inorganic filler particles may be any suitable inorganic filler particles such as for example barium sulphate, or a combination of barium sulphate with calcium carbonate, the particles preferably having a particle size of from 10 to 20 micron inclusive.
- the first composition preferably includes from 50% to 150% inclusive by mass of the thermosetting resin of the inorganic filler particles.
- the first composition may also include a pigment so that the outer face of the composite panel is coloured.
- the first composition is preferably applied to the mould by means of spraying or by means of brushing.
- a uniform thickness layer is applied, at a thickness of from 100 to 1000 micron inclusive.
- thermosetting resin After the first composition has been applied to the surface of the mould, the thermosetting resin is allowed to set to form an outer face of the first panel skin.
- the next optional step of the method of the invention is to apply a layer of a third connecting composition comprising a thermosetting resin and a catalyst therefor, to the product of step (1 )(b).
- thermosetting resin in the third composition may be any of those named above.
- the next step of the method of the invention is to form a layer of a fibrous reinforcing material, wetted with a second composition comprising a thermosetting resin and a catalyst therefor, onto the product of step (1)(b) or the product of the optional step above.
- the fibrous reinforcing material is preferably fibreglass, either in the form of chopped strand mat at weights of 300 kg/m 2 to 450 kg/m 2 or chopped strand applied by means of a chopper gun with a concurrent catalysed resin spray.
- thermosetting resin with which the fibrous reinforcing material is wetted may be any of those named above. Where a build is required over a steep mould surface or indentation, to prevent resin slump and to provide adequate reinforcement and prevention of air bubbles, the thermosetting resin may be thickened with a suitable thickener such as micronised silica, e.g Aerosil by Degussa, added to the resin in an amount of from 15 to 60 g/600 g of resin.
- a suitable thickener such as micronised silica, e.g Aerosil by Degussa
- the layer of fibrous reinforcing material wetted with the thermosetting resin and catalyst therefor preferably has a thickness of from 0,2 mm to 2,5 mm inclusive.
- the next step of the method of the invention is carried out before the thermosetting resins in the second composition and third composition (where present) have set, and involves placing an edging all around the edge of the product of step (1 )(c). It is important that the edging is placed in position before the setting of the thermosetting resins, in order to ensure intimate contact between the edging and the product of step (1)(c), and to ensure uniform thickness of the product of step (1)(c) below the edging.
- the edging is preferably formed from a plurality of lengths of wood or other suitable lignocellulosic material.
- the edging may also be a suitably profiled sheet metal edging.
- the edging preferably has a width or thickness of from 24 mm to 100 mm inclusive. Where two edgings are used, the edgings preferably each have a width or thickness of from 12 mm to 50 mm inclusive. In other words the spacing between the first and second panel skins is preferably from 24 mm to 100 mm inclusive.
- the edging When lengths of wood or other lignocellulosic material are used to form the edging, once the composite panel is complete, the edging is able to accommodate hinges, handles and other hardware, so that the composite panel may be used for the construction of a door or the like.
- a suitable material for the construction of the edging is pine or the like.
- the next step of the method of the invention is to allow the thermosetting resin to set to form a combination of the first panel skin with the edging attached thereto.
- the combination may optionally be removed from the first mould.
- the next step of the method of the invention is to form a second panel skin in a second mould which is substantially similar to the first mould.
- the first mould may be used as the second mould, or two substantially similar moulds may be used as the first and second moulds.
- the second panel skin is made in the same manner and from the same compositions as the first panel skin, i.e steps (1)(a) to (c) are repeated as steps (4)(a) to (c).
- thermosetting resins in the second composition and third composition (where present) have set, an edging is placed all around the edge of the product of step (4)(c). Again it is important that the edging is placed in position before the setting of the thermosetting resins, in order to ensure intimate contact between the edging and the product of step (4)(c), and to ensure uniform thickness of the product of step (4)(c) below the edging.
- the edging may be as described above.
- the next step is to allow the thermosetting resin to set to form a combination of the second panel skin with the edging attached thereto. At this stage the combination is removed from the mould.
- the next optional step of the method of the invention is to remove any excess material from the two combinations so that the two combinations are of substantially similar size and of the desired thickness. This may be achieved for example by passing each combination through a sander, so that the edgings, in combination with the panel skins, are dimensioned to their exact required thickness.
- the surfaces of the edgings which are not adhesively secured to one another in formation of the composite panel, may be laminated with a material that simulates the appearance of the outer faces of the composite panel.
- the next step of the method of the invention is to apply an adhesive composition to the edgings of the two combinations to join the edgings of the two combinations to each other to form an intermediate panel, including a cavity defined by the adhesively joined edgings.
- the adhesive composition may comprise polyvinyl acetate or an acrylic dispersion in water, optionally containing up to 20% by mass of a water dispersible MDI, which is a urethane prepolymer, i.e. Duthane 1042 by Industrial Urethanes of South Africa.
- a water dispersible MDI which is a urethane prepolymer, i.e. Duthane 1042 by Industrial Urethanes of South Africa.
- This step is preferably carried out in a press to ensure good adhesion of the two combinations to each other.
- the combination of step (3) may be placed on the product of step (4)(c), with the edging in contact with the product of step (4)(c). Again it is important that the edging is placed in position before the setting of the thermosetting resin, in order to ensure intimate contact between the edging and the product of step (4)(c), and to ensure uniform thickness of the product of step (4)(c) below the edging.
- the next step of the method of the invention is to allow the thermosetting resin to set to form an intermediate panel from the second panel skin and the combination, the intermediate panel including a cavity defined by the first and second panel skins and the edging.
- the next step of the method of the invention is to remove the intermediate panel from the second mould (and from the first mould, if necessary).
- the edging or edgings do not include one or more holes therethrough, formed during manufacture of the edgings for example, then, between steps (7) and (11), or between steps (10) and (11) there is included the step of forming one or more holes in the edgings to allow access to the cavity in the intermediate panel.
- holes may be drilled in one end of the intermediate panel through the edging, through which the polyurethane foam may be introduced, and holes may be drilled in the other end of the intermediate panel, to allow for the egress of air from the cavity.
- the next step of the method of the invention is to fill the cavity with a polyurethane foam to form the composite product.
- the polyurethane foam may be injected into the cavity through the hole or holes to fill the cavity at a density of from 25 kg/m 3 to 100 kg/m 3 inclusive.
- the polyurethane foam may be any suitable polyurethane foam, such as for example 100 parts by mass of a fire retardant polyol, Duthane 0514, to 120 parts by mass of Duthane 5005, both by Industrial Urethanes of South Africa, to give an in situ foam mass with a density of 40 kg/m 3 .
- the polyurethane foam serves the function of stiffening the composite panel. It adheres firmly to the two panel skins, it provides thermal insulation and maintains the two panel skins in parallel.
- the step of filling the cavity of the intermediate panel with polyurethane foam is preferably carried out with the intermediate panel in a press to restrain both panel skins of the intermediate panel.
- the composite panel may be trimmed to the size required.
- the method of the invention also includes the optional step of applying to the outer faces of the composite panel a decorative coating, such as for example a pigment in an oil, the coating being applied by means of a spray gun or the like.
- a decorative coating such as for example a pigment in an oil
- this is applied as a wash coat which is worked into the surface of the outer faces. This is then allowed to dry, after which the oil binds the pigment to the surface of the outer faces.
- sealant coating such as for example an acrylic or a polyurethane.
- the advantages of the method of the invention are that two substantially identical panel skins are used to form a composite panel which results in the fact that any stresses in one panel skin are perfectly balanced by those in the other panel skin, thus providing the composite panel with strength and dimensional stability.
- FIG. 1 to 3 there is shown two combinations 10, 12 each consisting of a panel skin comprising an outer face 14 formed from a first composition as described above and a layer 16 of a fibrous reinforcing material adhered to the outer face 14 as described above, and an edging 18 formed from lengths of pine.
- the edgings 18 are adhered to each other with a suitable adhesive composition, to form an intermediate panel containing a cavity defined by the edgings 18. This cavity is then filled with a polyurethane foam 20 to form the composite panel of the invention.
- first and second panel skins 40, 42 each consisting of an outer face 44 formed from a first composition as described above, and a layer 46 of a fibrous reinforcing material adhered to the outer face 44 as described above.
- An edging 48 formed from length of pine is located between the two panel skins 40, 42.
- the panel skin 40 is first made by the method described above, whereafter the edging 48 is attached thereto. Thereafter the second panel skin 42 is made by the method described above and the combination of the first panel skin 40 and edging 48 is then adhered thereto as described above. There is thus formed an intermediate panel containing a cavity defined by the first and second panel skins 40, 42 and the edging 48. This cavity is then filled with a polyurethane foam 50 to form the composite panel of the invention.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
- Mathematical Physics (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2001276577A AU2001276577A1 (en) | 2000-07-31 | 2001-07-23 | Method of making a composite panel |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ZA2000/3864 | 2000-07-31 | ||
ZA200003864 | 2000-07-31 | ||
ZA2001/3061 | 2001-04-12 | ||
ZA200103061 | 2001-04-12 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2002009930A2 true WO2002009930A2 (fr) | 2002-02-07 |
WO2002009930A3 WO2002009930A3 (fr) | 2002-05-02 |
Family
ID=27145484
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IB2001/001308 WO2002009930A2 (fr) | 2000-07-31 | 2001-07-23 | Procede de fabrication d'un panneau composite |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU2001276577A1 (fr) |
WO (1) | WO2002009930A2 (fr) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2004062893A1 (fr) * | 2002-12-13 | 2004-07-29 | Saint-Gobain Vetrotex France S.A. | Procede et dispositif de fabrication d'une plaque composite |
ES2238105A1 (es) * | 2002-02-21 | 2005-08-16 | Hermanos Llorente, S.L. | Procedimiento de fabricacion de paneles tipo sandwich. |
WO2011051085A1 (fr) * | 2009-10-28 | 2011-05-05 | Kraussmaffei Technologies Gmbh | Élément sandwich isolé et dispositif pour fabriquer cet élément |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB877615A (en) * | 1958-10-02 | 1961-09-20 | Percy Henry Alcock | Improvements in or relating to the production of laminated structures |
US3573144A (en) * | 1969-08-11 | 1971-03-30 | Ralph A Andersen | Sandwich panel type structural elements and method of making same |
DE19814039A1 (de) * | 1998-03-30 | 1999-10-07 | Koegel Fahrzeugwerke Ag | Sandwichelemente aus Kunststoff-Deckschichten und einem Kern zur Herstellung mobiler, temperaturgeführter Container |
-
2001
- 2001-07-23 WO PCT/IB2001/001308 patent/WO2002009930A2/fr active Application Filing
- 2001-07-23 AU AU2001276577A patent/AU2001276577A1/en not_active Abandoned
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB877615A (en) * | 1958-10-02 | 1961-09-20 | Percy Henry Alcock | Improvements in or relating to the production of laminated structures |
US3573144A (en) * | 1969-08-11 | 1971-03-30 | Ralph A Andersen | Sandwich panel type structural elements and method of making same |
DE19814039A1 (de) * | 1998-03-30 | 1999-10-07 | Koegel Fahrzeugwerke Ag | Sandwichelemente aus Kunststoff-Deckschichten und einem Kern zur Herstellung mobiler, temperaturgeführter Container |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
ES2238105A1 (es) * | 2002-02-21 | 2005-08-16 | Hermanos Llorente, S.L. | Procedimiento de fabricacion de paneles tipo sandwich. |
WO2004062893A1 (fr) * | 2002-12-13 | 2004-07-29 | Saint-Gobain Vetrotex France S.A. | Procede et dispositif de fabrication d'une plaque composite |
US7674495B2 (en) | 2002-12-13 | 2010-03-09 | Ocv Intellectual Capital, Llc | Method and device for making a composite plate |
WO2011051085A1 (fr) * | 2009-10-28 | 2011-05-05 | Kraussmaffei Technologies Gmbh | Élément sandwich isolé et dispositif pour fabriquer cet élément |
Also Published As
Publication number | Publication date |
---|---|
WO2002009930A3 (fr) | 2002-05-02 |
AU2001276577A1 (en) | 2002-02-13 |
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