IES66089B2

IES66089B2 - A method for the manufacture of a part of a door frame and to the door frame itself

Info

Publication number: IES66089B2
Authority: IE
Inventors: Alphonsus O'mara
Original assignee: Wen Plast Res & Dev
Priority date: 1995-06-07
Filing date: 1995-06-07
Publication date: 1995-12-13
Also published as: GB2301792A; GB2301792B; IES950419A2; GB9611710D0

Abstract

A method for the manufacture of a seamless aseptic door frame comprises providing first and second moulds 30,40, the first having a stepped well in its surface the second having a projection 41 fitting the mouth of the well; coating each mould with an isophthalic gel coat then with a polyester and then applying layers of glass fibre 37,38 and polyester in a defined pattern; providing a core element 39 in the well of the first mould folding the glass fibre about that element and applying a layer of polyester; closing the mould by placing the second mould over the first mould to seal the well; pressing at 69.9-172.3kPa; removing the formed door from the mould and finishing it.

Description

A METHOD FOR THE MANUFACTURE OF A PART OF A DOOR FRAME AND TO THE DOOR FRAME ITSELF This invention relates to a method for the manufacture of a part of a door frame and to the door frame itself. In particular, it relates to a method for the manufacture of a seamless aseptic part of a door frame.

The invention, therefore, provides a method for the manufacture of a seamless aseptic part of a door frame and to the door frame itself which method comprises the steps of: (a) providing a first mould and a second mould, the first mould having, in cross-section, a first step, a second lower step, a third still lower step and finally a fourth step on the same level as the first step so as to provide a stepped well; the second mould having the width of the first mould and having a projection, the width of which projection is equal to the distance between the first step and the fourth step; (b) coating the first mould and the projection of the second mould with isophthalic gel coat and allowing the gel coat to become tacky; (c) coating the first mould with a first layer of a polyester; (d) providing in the well a first fibre glass layer; (e) coating the first fibreglass layer with a second layer of a polyester; (f) providing in the well a second fibreglass layer the ends of which layer are substantially longer than the overall height of the well; (g) placing an L-shaped core filler In the well having the shape and configuration of the well; (h) folding the ends of the second layer over the core filler so as to cover the core filler and be in overlapping relationship; (i) coating the exposed second glass fibre layer with a third layer of a polyester; (j) placing the second mould over the first mould so as to enable the projection to seal the well and provide a combination mould; (k) placing the combination mould in a press at between 68.9kPa and 172-3kPa (10-25 psi); (l) removing the combination mould from the press and. removing the thus formed part of a door frame from the mould; and (m) finishing the part of the door frame» Preferably, the combination mould is subject to pressure in step (k) for a period of between. 70 and 80· minutes,, preferably 75 minutes.

Preferably, the combination mould is subject to pressure in step (k) 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.

The invention will be understood in greater ' detail from the following description of a preferred embodiment thereof given by way of example only and with reference to the accompanying drawing which is a cross-sectional diagrammatic view of a mould part of a and a door frame showing the stages of manufacture.

Referring now to the drawing, there is shown a first mould 30 and a second mould 40«, The first mould has a first step 31, a second lower step 32 and a third still lower step 33 followed by a fourth elevated step 34 having the same level as the first step 31 thus creating a stepped well 35. The well 35 is coated with an isophthalxc coating (not shown) which is allowed to became tacky. The well 35 is coated with a polyester layer 36 followed by the placement of a first fibre glass layer 37 so as to cover the well 35 in the manner of a blanket.

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 a chemical reaction, forms a gel and subsequently cures the polyester resin.

The thickness of the layer 37 is preferably about o.45am and the ends thereof terminate at the top of the well 35. The first layer 37 is saturated with a further coating of the polyester layer (not shown) followed by the placement of a second fibreglass layer 38 so as to cover the well 35 in the manner of a blanket- The thickness of the second layer 38 is preferably 0.9mm the ends 38a, 38b of which are sufficient in length beyond the top of the well 35 so as to have a combined length greater than the length of the well 35.

A cor® filler 39 is placed in the well 35 over the layer 38. The core filler 39 may comprise any suitable material such as timber, PVC, cork, lead lined marine ply, urethane or a fire break material. The cross-sectional shapes of the filler 39 is L-shaped so that the filler 38 mates with the shape of the well 35. The ends 38a, 38b of the second layer 38 are folded over the filler 39 so as to embrace the filler 39 and overlap it. The ends 38a, 38b are saturated with a still further polyester layer (not shown).

The second mould 40 is of constant thickness throughout its cross-section save for a mid-section which has a projection 41 corresponding in width to the width of the well 35 such that when the second mould 40 is placed on top of the first mould 30, the well 35 is closed toy the projection 41.

The surface of the projection 41 is coated with an isophthalic gel coat layer (not shown.) which is allowed to become tacky.

The second mould 40 is lowered into position over the first mould 30 so that the projection 41 closes the well 35 and presses down on the exposed second layer 39 thereby forming a combination mould.

The combination mould is placed in a press at a pressure of between 68.9kPa-172.3k9a (io-25pei) for between 70-80 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 mould is removed from the press, the mould 40 separated from the mould 30 so as to enable the thus formed part of the door frame (not shown) to be removed and subject to finishing.

There is thus formed, depending on the length 5 thereof, either one of two aseptic seamless jambs of a door frame or the an aseptic seamless lintel of a door frame. By combining other similarly formed parts of a door frame, a door frame can be assembled from the relevant parts thereof.

The invention is not limited by or to the specific embodiment described which can undergo considerable variation withouth departing from the scope of the invention.

Claims

CLAIMS:

1. A method for the manufacture of a seamless aseptic part of a door frame and to the door frame itself which method comprises the steps of: (a) providing a first mould and a second mould, the first mould having, in cross-section, a first step, a second lower step, a third still lower step and finally a fourth step on the same level as the first step so as to provide a stepped well; the second mould having the width of the first mould and having a projection, the width of which projection is equal to the distance between the first step and the fourth step; (b) coating the first mould and the projection of the second mould with isophthalic gel coat and allowing the gel coat to become tacky; (c) coating the first mould with a first layer of a polyester; (d) providing in the well a first fibre glass layer; (e) coating the first fibreglass layer with a second layer of a polyester; (f) providing in the well a second fibreglass layer the ends of which layer are substantially longer than the overall height of the well; (g) placing an L-shaped core filler in the well having the shape and configuration of the well; (h) folding the ends of the second layer over the core filler so as to cover the core filler and be in overlapping relationship; (i) coating the exposed second glass fibre layer with a third layer of a polyester; (j) placing the second mould over the first mould so as to enable the projection to seal the well and provide a combination mould; (k) placing the combination mould in a press at between 68.9kPa and l72.3kPa (10-25 psi); (l) removing the combination mould from the press and removing the thus formed part of a door 5 frame from the mould; and (m) finishing the part of the door frame.

2. A method as claimed in claim 1 wherein .the combination mould is subject to pressure in step (k) 10 for a period of between 70 and SO minutes, preferably 75 minutes.

3. A method as claimed in claim 1 or 2 wherein the combination mould is subject to pressure in step (k) at 15 a temperature of between 17°C and 22 e C, preferably 20»C.

4. A method as claimed in any of claims 1-3 wherein the polyester layer comprises a pre-accelerated 20 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. 25

5. A method for the manufacture of a, seamless aseptic part of a door and to the door form itself, substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.