Composite door structure and method of forming a composite...

Details Composite door structure and method of forming a composite... Composite door structure and method of forming a composite...

B - Operations, Transporting

29

C

B29C 69/02 (2006.01) B29C 69/00 (2006.01)

Patent

CA 2491046

A method of forming a composite door is disclosed. The method comprises: mixing together a thermoplastic polymer with an organic fibrous material in a ratio such that the organic fibrous material constitutes 40 to 60 percent by weight of the mixture; extruding the mixture under heat and pressure to create a thin sheet form; cutting the sheet to a predetermined size; removing material from at least one surface of the sheet to create a uniform surface of exposed fibrous particles that has a homogenous appearance devoid of obvious fibrous particles; thermoforming the sheet to impart to the at least one surface an exterior three dimensional door surface to create a thin door facing; and assembling two of the termoformed thin door facings, a peripheral frame and a core material into a door.

L'invention porte sur un procédé de réalisation d'une porte composite comportant les étapes suivantes: mélange d'un polymère thermoplastique avec un matériau fibreux organique dans un rapport tel que ledit matériau constitue de 40 à 60 % en poids du mélange; extrusion du mélange à chaud et sous pression pour créer une feuille mince; découpage de la feuille aux dimensions voulues; élimination de matériau sur l'une au moins des surfaces de la feuille pour créer une surface uniforme de particules fibreuses exposées, d'apparence homogène et exempte de particules fibreuses saillantes; thermoformage de la feuille pour donner à au moins l'une de ses surfaces l'aspect d'une porte extérieure à surface en 3D, la feuille devant servir de façade mince de porte; et assemblage de deux façades minces, du cadre périphérique et du matériau de l'âme, pour constituer la porte.

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