Method for manufacturing of composite door panel using injection molding technology

Abstract

A method to produce one-piece high-density panel skin (outer part of the door panel) using a specially designed 25 ton mold operated on a 3000 ton injunction molding machine using performance engineering grade poly phenyl impact copolymer as raw material.The two injection molded panels are joined using a custom extruded aluminum frame, with a provision for an improved lock along the whole length and hinges, fitted with specially designed hot plate welded skin holder, subsequently filled with polyurethane for rigidity, strength and high insulation valve. For additional reinforcement for the entry door, 18 gauge CRC steel barrier is embedded in rigid polyurethane core.A door panel produced by the above methods.

Description

[0001]This application claims priority of Pakistani patent application Serial No. 501 / 2006, filed May 20, 2006, the disclosure of which is incorporated herein in its entirety by reference for all purposes.FIELD OF THE INVENTION[0002]The present invention generally relates doors and specifically to a composite door panel, which would be less costly for houses and office construction, would guarantee against corrosion.BACK-GROUND OF THE INVENTION[0003]The house building industries are developing very fast but no work has been done to change the material of door and windows in a house or office. The front entry doors and interior doors for residential houses and offices have historically been made of wood or steel, recently fiber glass and vinyl doors are available. The wooden doors deteriorate with time and need a great care for its maintenance. Steel doors dent very easily and are prone to corrosion. Fiberglass doors are comparatively expensive and vinyl doors generally lack the aest...

AI Technical Summary

Benefits of technology

[0010]In another embodiment, the surface of the skin of the door panel is mechanically roughened to create strong adhesion between the skin and adhesive.

[0012]In another embodiment of the invention, the method comprises filling the remaining space of the inner portion of the skin with polyurethane for rigidity, strength and high insulation value with the help of a specially designed press machine, which hold the skin during filling.

[0013]In a further embodiment, the invention is an improved method for manufacturing of door panels using injection molding technology to produce one-piece high-density panel skins, wherein the method comprises joining of the two injection molded panel skins, using a specially designed 25 ton mold operated on a 3000 ton injection molding machine, performance engineering grade mechanically roughened polypropylene impact copolymer as raw material, and an improved custom extruded aluminum frame with provision of non-returnable lock and hinges, fitted with specially designed hot plate welded skin holder, subsequently filled with polyurethane for rigidity, strength and high insulation value, a reinforcement of 18 gauges cold rolled coil (CRC) steel barrier embedded in rigid polyurethane core, wherein the surface of the skin of the door panel is mechanically roughened to create strong adhesion between the skin and adhesive.

Problems solved by technology

The house building industries are developing very fast but no work has been done to change the material of door and windows in a house or office.

The wooden doors deteriorate with time and need a great care for its maintenance.

Steel doors dent very easily and are prone to corrosion.

Fiberglass doors are comparatively expensive and vinyl doors generally lack the aesthetic quality.

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