Pigmented Compression Molded Door Skins
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Solution Overview
Problem
Traditional compression molded door skins have a pale gray, streaked appearance, requiring expensive painting or staining for architectural acceptability, which can lead to discoloration during trimming and obscure patterns, and may become tacky due to scratches and abrasions.
Innovation Solution
Development of pigmented compression molded skins with uniform color distribution throughout, using compositions of polyester resin, styrene monomer, polystyrene, calcium carbonate, chopped fiber glass, and pigments like titanium oxide, ferric oxide, organic green, organic blue, and carbon black, allowing for trimming without color discontinuities and eliminating the need for painting or staining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional compression molded skins are used without pigments, then the manufacturing process is simpler and cost lower, but the skins have a pale gray, streaked appearance requiring expensive painting or staining
Solution Approach 1:
The patent changes the chemical composition parameters of the skin material by incorporating pigments (such as titanium oxide, ferric oxide, organic green pigment, organic blue pigment, and carbon black) into the compression molded skin formulation. This modification transforms the skin's inherent color from pale gray and streaked to uniform architectural colors, eliminating the need for subsequent painting or staining operations.
Solution Approach 2:
The patent creates a composite material system by combining traditional skin components (polyester resin, polystyrene, calcium carbonate, chopped fiber glass) with pigment particles. This composite formulation achieves both structural integrity and uniform coloration throughout the skin material, resolving the contradiction between manufacturing simplicity and aesthetic appearance.
2Object-affected harmful factors
If painting or staining is applied to achieve architectural acceptability, then the aesthetic appearance is improved, but the cost increases and time consumption increases
Solution Approach 1:
The patent incorporates pigment coloring into the skin material during the initial compression molding process, performing the coloring action beforehand rather than requiring subsequent painting or staining operations. This preliminary action eliminates the need for additional finishing steps, thereby reducing both time consumption and associated costs while maintaining architectural acceptability.
3Object-affected harmful factors
If painting or staining is applied to achieve architectural acceptability, then the aesthetic appearance is improved, but the surfaces become prone to scratching and abrasion resulting in tacky appearance
Solution Approach 1:
The patent changes the material composition by integrating pigments throughout the skin matrix, creating a uniformly colored structural material rather than a surface coating. This fundamental change in material parameters gives the color inherent strength and scratch resistance, as the pigment becomes part of the skin's structural integrity rather than a separate layer that can be damaged.
4Object-affected harmful factors
If painting or staining is applied to achieve architectural acceptability, then the aesthetic appearance is improved, but the patterns impressed on the exterior surface are obscured
Solution Approach 1:
The patent modifies the material composition to include pigments that provide uniform coloration without forming a opaque surface layer. This compositional change allows the skin to maintain its natural surface characteristics and impressed patterns while achieving architectural acceptability through inherent coloration, thus preserving pattern clarity.
5Length of moving object
If trimming is performed on traditionally colored skins, then the door size is adjusted, but color discontinuities and discoloration occur at the trimmed edges
Solution Approach 1:
The patent changes the color distribution parameter from surface-level application to uniform throughout-the-thickness incorporation of pigments. This ensures that when trimming occurs, the freshly exposed edges display the same uniform color as the rest of the skin, eliminating color discontinuities and discoloration issues.
6Adaptability or versatility
If multiple pigments are added to achieve various colors, then the product versatility is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent changes the formulation parameters by incorporating a standardized set of pigment types (titanium oxide, ferric oxide, organic green pigment, organic blue pigment, carbon black) at controlled concentrations (0.2% to 20% by weight). This systematic approach to pigment incorporation allows for multiple color variations while maintaining a consistent and manageable manufacturing process, avoiding excessive complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The pigmented skins maintain color uniformity during trimming, reduce the appearance of scratches and abrasions, and preserve pattern clarity, offering cost savings and improved weathering characteristics compared to conventionally stained or painted doors.
Implementation Method 1
white, brown, red, green, blue or black color being distributed uniformity throughout the skin
Implementation Method 2
subjected to pressures from 600 to 1,500 psi for a cure period from 60 to 200 seconds
Implementation Method 3
normally thermoset materials such as phenolics, urea, melamines and polyesters
Data Source
Figure 1
AI summary
In a door constructed of spaced apart compression molded skins (11, 12) reinforced with fiber glass with a core space (18) between the skins (11, 12) filled with foam to construct the door (10), an improved skin (11 or 12) for such door is constructed by adding specific pigments to the raw materials for such skins before compression molding occurs to achieve a surface which is superior in appearance to the skins (11, 12) of such door (10) which is painted and/or stained after such skins (11, 12) are compression molded and converted into a door. The specific pigments employed are titanium oxide [TiO2] ferric oxide [Fe2O3], organic green pigment, organic blue pigment and carbon black and are blended in different percentages to achieve different colors without loss of the integrity of the skin (11 or 12).