FIG. I shows the cross-section of composite door panel.
FIG. II shows main outlook of the composite door panel.
FIG. III shows the position of 18 gauge CRC sheet, exclusive requirement of “entry door”.
FIG. IV shows the dimension of the skin holder and hot plate.
FIG. V shows the position of skin holder in the composite door panel.
In Figures the numeral 1 is the injection molded surface (skin of the door panel), 2 is slush molded rigid PV core, 3 is hot plate (Welded Skin holder), 4 is a layer of adhesive coating for skin and core, 5 is extruded aluminum frame, 6 is 18 gauge CRC sheet, 7 is the knob/lock of the door.
An embodiment of the invention is a new method for manufacturing of composite door panel, which is an improvement over the patent application Serial No. 961/2004, filed in Pakistan, which is hereby incorporated herein in its entirety by reference.
An embodiment of the invention is a door which is a great improvement over other products available in the market as its price is competitive, would not dent or corrode and would not absorb moisture, warp, and rot and has longer life and maintenance free performance over competitive products. Also the aesthetic appearance could match any home design.
An embodiment of the invention comprises of following:
The injection molded surface (skin of the door) marked 1 is prepared by using injection molding technology, then the skin holder (3) are hot welded with hot melt joining of the two. Then the specially designed aluminum frame (5) is fixed with the help of an adhesive, with provision for lock and hinges and the 18 gauge CRC sheet (6) if required. The skin holder is fixed as shown in FIG. V. After fixing the skin holder (3), 18 gauge CRC sheet (6) and aluminum frame (5), the skins are then shifted to press machine, where polyurethane core is filled under constant pressure and the door of the invention is completed by applying the hinges and locks and then finished for painting.
An embodiment of the present invention is a method using the improved extruded aluminum frame, whereby a non returnable lock is added along the full length of aluminum profile to ensure perfect locking system and further the surface of poly phenyl plastic is mechanically roughened to create strong adhesion of adhesive and plastic as prior to this it was observed that during accidental hit on the edge of the door, there was no grip of plastic with aluminum, resulting in dislocation. Hence in order to improve the grip this invention has been made, as there is no adhesive is developed by now, which can grip poly phenyl plastic, therefore only possibility is to grip this plastic surface mechanically.
For further strength requirements of entry doors an additional reinforcement of 18-Gauge CRC steel sheet barrier is embedded in the rigid polyurethane core.
The doors of the present invention are manufactured using injection molding technology to produce one-piece high-density panel skins using a specially designed 25 Ton molded operated on a 3000 Ton injunction molding machine using performance engineering grade polyphenyl impact copolymer as raw material having the following typical properties:
The two injection molded skins are joined using a specially designed extruded aluminum frame, with provisions of locks and hinges, fitted with specially designed hot plate welded skin holders, subsequently filled with polyurethane for rigidity strength and high insulation value.
The skin holders as described in FTG TV are the main feature of the invention and their holding strength is calculated as under:
i. Holding strength of rigid polyurethane (PU)=2.5 kg/in2
ii. Total targeted force to hold skin=100 kg/side
iii. Force generating medium=25% Chemical Bond & 75% Mechanical Bond
iv. Thickness of PU=½ inch
2.95=3.142×D×0.5
For binding the polyurethane in between the two skin adhesive coating is done with 3M Fast bond 30 or 3M Fast bond 40 adhesive, which has shown the best result as the base of the said adhesive is polychloropropane. The skin holders are joined with the skin with hot melt joining (hot welding).
Number | Date | Country | Kind |
---|---|---|---|
501/2006 | May 2006 | PK | national |