• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
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  • 优先权
    • 专利摘要:
    The invention relates to a recycling piece (12) for the production of a polyester resin-based fiber-reinforced door (1). The fiber-reinforced door (1) comprises the frame of a door panel (10) with sandwich structure, which is made by compression molding of pure plastic composite and a recycling piece (12), and which frame of the door panel (10) consists of ethylenically unsaturated polyester resin-based fiber-reinforced polyester matrix (4) which provides mechanical durability to the door panel (10), and a gelcoat outer layer (3) which can be applied to said fiber-reinforced polyester matrix during compression molding and which provides chemical durability to the door panel, which gelcoat outer layer is based on ethylenically unsaturated polyester resin which has been cured in a mold, before said fiber-reinforced polyester matrix is applied to said gelcoat layer.
    公开号:FI20215748A1
    申请号:FI20215748
    申请日:2021-06-24
    公开日:2021-12-25
    发明作者:Juha-Matti Aho
    申请人:Muovilami Oy；
    IPC主号:
    专利说明:

    The invention relates to a recycling section for the production of a polyester-resin-based fiber-reinforced door and to a polyester-resin-based, fiber-reinforced door.
    The invention also relates to a method for manufacturing a polyester resin-based, fiber-reinforced door having a recycled portion and to the use of a recycled portion for making a polyester resin-based door.
    - There is a chemical- and water-resistant door on the market, which is a seamless, fiberglass-reinforced, molded polyester resin-based door. This door can be, for example, a fire door, an X-ray door, a revolving door, a decibel door, a swing door or a sliding door. The outer surface of the door panel is glazed by making it from gelcoat, and beneath this outer surface of gelcoat (hereinafter the gelcoat outer layer) is a fiberglass-reinforced polyester matrix consisting of several layers of glass-fiber-reinforced polyester polymer. Such a door is lightweight and its door leaf is resistant to chemicals, water and moisture. The outer layer of Gelcoat is smooth and also gives the door leaf resistance to dust and dirt.
    Now that environmental standards are tightening, there has been a need to reduce the amount of virgin plastic in plastic products, including the aforementioned molded doors - by working to recycle door materials. At the same time, the resistance of the molded door to chemicals, water resistance, mechanical stress and impact resistance should be maintained.
    The above objects are achieved by a recycling section for producing a polyester resin-based fiber-reinforced door according to claim 1, and a polyester resin-based fiber-reinforced door thus obtained comprising a recycling section and a method of manufacturing such a door. More particularly, the invention relates to a recycling section for making a polyester resin-based fiber-reinforced door. The fiber-reinforced door comprises a body of a sandwich-structured Lo door panel made of a molded plastic composite and a recycled portion, the body of the door panel being made of polyester-impregnated polyester-resistant polyester-resistant polyester to give the door panel a gelcoat outer layer based on an ethylenically unsaturated polyester resin which can be cured on the door sheet during molding prior to providing said fiber-reinforced polyester matrix on top of said gelcoat outer layer.
    The frame of the door panel comprises two parallel panel elements, thus seamlessly spaced apart by means of a bridge element, so that a hollow inner layer of the door panel remains in the space defined by said panel elements and the bridge element arranged to connect them.
    An optional filling material can be placed in the inner layer, in which the bridge element is transverse to the direction of the plate elements and rotates the longitudinal and transverse ends of the plate elements.
    The impact resistance of a molded door leaf frame to a hard object, tested in accordance with standard SFS-EN 950, shall be such that the diameter of the impact mark on the door leaf frame is not more than 1.5 mm and the average for depressions is not more than 1 mm.
    The recycling part comprises a one-piece door leaf body with two plate elements parallel to each other, parallel to each other by means of a bridge element.
    The door panel body of the recycled section is made of a fiber-reinforced polyester matrix which lacks a major portion of the gelcoat outer layer, preferably the entire gelcoat outer layer.
    The invention also relates to a polyester resin based fiber reinforced door comprising - a recycling section.
    The door then comprises a sandwich door leaf frame made by molding both virgin plastic composite, allowing the gelcoat coatings to harden on the inner surface of the two different mold halves and laminating one or more fiber-reinforced polyester-coated coatings a fiber-reinforced polyester matrix based on an unsaturated polyester resin by arranging a recycled portion of gelcoat between the outer layers of the laminated fiber-reinforced polyester matrix and sealing the mold. The invention further relates to the use of a recycled part in the manufacture of a polyester resin-based fiber-reinforced door, wherein the fiber-reinforced door is produced by compression molding and the recycled part comprises a one-piece door leaf body with two parallel bridge elements spaced apart the door leaf frame of the recycled plastic composite section is made of a fiber-reinforced polyester matrix.
    By one-piece recycling part is meant that the recycling part is a single, continuous piece.
    By seamless of the door leaf is meant herein that the outer layer of gelcoat covering the surface of the door leaf has no slots or openings permeable to water or air. The outer layer of gelcoat thus forms an airtight and watertight surface on the door panel made of fiber-reinforced polyester. The outer layer of Gelcoat has a smooth surface quality, which means that it is also dirt and dust repellent.
    By the inner layer of the door leaf is meant the space which is left between the compressed halves of the fiber-reinforced polyester matrix of the door leaf when these door plates are connected by a transverse bridge element.
    Each half of the door panel in turn comprises a plastic composite laminated to the half of the mold (part of the mold). The plastic composite comprises a polyester resin-based, fiber-reinforced laminate (fiber-reinforced polyester matrix) having a cured gelcoat outer layer on the surface facing the mold.
    - The invention is based on the use of a previously manufactured door panel in which the outer layer of its gelcoat has been sanded off. When the outer layer of gelcoat is removed from the top of the door leaf, it can be used almost as such or slightly modified in the molding of a new door leaf.
    Since the surface of a door made of recycled door panels does not have an outer layer of gelcoat, the properties of a door made of such a pair of door panels are considerably different from those of a corresponding door with an outer layer of gelcoat on the door panels. The recycled part does not meet the resistance of chemicals and oxidizing agents N determined for at least two hours or at least 16 hours according to EN 14688 for one or more of the following substances: acid such as acetic acid (10% v / v), S 25 base such as sodium hydroxide (5% ( m / m), an alcohol such as ethanol (70% v / v), a bleaching agent such as sodium hypochlorite, an oxidizing agent such as methylene blue (1% m / m) and a salt I such as sodium chloride (50% v / v)). a e Furthermore, the surface of the recycled part does not meet the resistance of cold liquids as determined in accordance with DIN 68861 (SFS-EN 12720) for three or more of the following substances: coffee, mild detergent, cola drink, ink (water-resistant),
    N olive oil, paraffin oil, acetone, hydrochloride, milk, animal blood (the liquid causes at least a moderate change in the surface of the 3 recycled parts).
    Cold liquids stain the surface of the recycling section because the surface of the recycling section is formed of a fiber-reinforced polyester matrix, which makes its surface rough and easily collects dirt and dust. The one-piece recycled part according to the invention is used for the production of a polyester resin-based fiber-reinforced door. The fiber-reinforced door is produced by compression molding, in which case the recycling part comprises a one-piece door leaf body with two parallel, oppositely spaced, plate elements arranged by means of a bridge element. In the recycling section of the plastic composite, the frame of the door panel is made of a fiber-reinforced polyester matrix. - A fiber-reinforced door is manufactured using a recycled part as follows: a) Two mold parts (mold halves) are formed, with each plate element of the door leaf and the bridge element connecting them being adapted for production. b) A gelcoat coating (glaze) made of polyester resin is first applied to the surface of both mold parts and at least one fiber-reinforced resin layer based on an ethylenically unsaturated polyester resin reinforced with a fibrous material is laminated on the cured gelcoat coating. c) Before compressing the mold parts together, a recycle part is placed between the fiber-reinforced polyester matrix layers, which polyester matrix layers are laminated on a cured gelcoat coating arranged on the inner surface of each mold part. - The recycling part comprises a one-piece door leaf body with two parallel plate elements positioned at a distance from each other by means of a bridge element. N d) The mold is closed by compressing said two mold parts together while heating. 3 + 25 - In the recycled part, the door panel body is made of a fiber-reinforced polyester matrix and - it is missing the main part of the gelcoat outer layer, preferably the entire gelcoat outer layer.
    X S In the above method of manufacturing a fiber-reinforced door, only one layer of fiber-reinforced polyester resin is laminated on the cured gelcoat coating in each mold half. By using the recycled part, a considerable advantage is obtained that the proportion of the virgin fiber-reinforced polyester matrix in the molded door can be reduced compared to the molded door made of the virgin plastic raw material. The amount of reinforcing fiber can also be reduced by using the recycled part by 50 to 90%, respectively, compared to a molded door made of virgin plastic raw material.
    5 In this way, the door frame and door materials can be recycled several times, in principle continuously. In one embodiment of the invention, the recycling section is made from a blank of the recycling section having a window opening. A window opening is formed in said recirculation section blank by removing the window from the door panel body.
    - In another embodiment of the invention, the recycling part is made of a blank of the recycling part with at least one fitting opening formed by removing the fitting from the door panel body.
    In a further embodiment of the invention, the recycling part comprises filling pieces and optionally an adhesive used for gluing the filling pieces. The recycled part is then made by fitting the filling pieces into the openings in the blank of the recycled part used in the manufacture of the recycled part. The filling pieces are either filling pieces removed from the door leaf or separately made filling pieces.
    As described above, it is advantageous to utilize the fillings used for the removal of window openings and fittings, which would otherwise be wasted.
    In a further preferred embodiment of the invention, the polyester resin used for the preparation of the polyester matrix is formed by reacting at least one ethylenically unsaturated dicarboxylic acid or its acid anhydride with at least one polyol.
    Preferably, the polyester resin used to prepare the polyester matrix is formed by reacting at least one ethylenically unsaturated dicarboxylic acid - or an acid anhydride thereof or a mixture of an unsaturated dicarboxylic acid and a saturated = dicarboxylic acid with at least one polyol.
    00 = Ethylenically unsaturated dicarboxylic acid or an acid anhydride thereof is selected from the group consisting of: maleic acid, maleic anhydride, fumaric acid, N 30 - itaconic acid, phthalic acid, phthalic anhydride, phthalic anhydride, ththalic acid, tertiary anhydride , dimethyl terephthalate or recycled terephthalate.
    The polyol is then selected from the group consisting of glycols such as ethylene glycol, propylene glycol; diols such as 1,3-propanediol, 1,4-propanediol, 1,4-butanediol, 2,2-methyl-1,3-propanediol, 2-methyl-1,3-propanediol; glycol ethers; and triols such as glycerol and trimethylpropane.
    In the following, the invention is further illustrated by reference to the accompanying figures. Figure 5 illustrates, for comparison, a door made of a virgin plastic material (reference pattern).
    Figure 1 illustrates a finished access door mounted on a door frame, viewed directly from the front. Fig. 2 is an oblique top view of a blank of a recycled part of a door leaf. Figure 3A illustrates a perspective view of a recycle part blank corresponding to the manufacture of a recycled part. Fig. 3B shows a perspective view, from a slightly different angle of view than in Figs. 3A, of the production of the recycling section by filling the openings in the blank of the recycling section. Figure 4 schematically illustrates the manufacture of a door mold. Figure 5 shows a door panel made of a virgin material with a schematic cross-sectional pattern. Figure 6 shows a schematic cross-sectional view of a door panel made partly of virgin and partly of recycled material. N Fig. 7 illustrates a schematic cross-sectional pattern of a door panel N comprising only a recycled portion or a blank thereof. O
    O + The diagram of Fig. 8 illustrates a method of manufacturing a door including a recycled portion.
    I = © 25 - In the following, the main features of the invention will first be discussed with the aid of Figures 1 to 7. +
    N = Figure 1 schematically shows a door 1 mounted on the door frame 20 and the door S having a recirculating part 12. The door 1 is here a revolving door 1a. The frame of the door plate 10 of the door 1 has a fiber-reinforced polyester resin matrix and a so-called gelcoat outer layer 30 on it. The body of the door panel 10 has a sandwich construction and is made by molding a plastic composite with a portion of recycled material. The door 1 shown in Fig. 1 comprises a lock 5 mounted on the door plate 10; 53 and button 5; 52. The door further comprises a frame 20 rotating the door opening into which the door plate 10 of the door 1 is arranged by means of hinges 5; 51. The door 1 may also comprise a sliding rail running in the width direction of the door opening, to which the door plate 10 of the door can be fitted by means of a roller or a corresponding sliding part. Figure 2 shows a recycled section blank 12a formed of a recycled door panel 10; 11. Fig. 3A shows another recycled door panel door panel 10 formed of a recycled blank 12a having a window opening 2. Fig. 3A illustrates how the gelcoat outer layer on the surface of the door panel 10 is removed to form the recycled blank 12a. Figure 3B shows another recycled door panel from which the recycled section blank 12a is formed. The recycled portion blank 12a shown in Fig. 3B has a window opening 2 and a gelcoat outer layer on its surface. Fig. 3B also illustrates how a filling piece 45 is mounted in the window opening of the door panel 10. Fig. 4 shows a schematic cross-sectional view of a mold 7 available for pressing a door. The shape of each mold part is adapted to the respective plate element 101,102 and the bridge element 103 connecting them. O Door 1 made of recycled part 12; The inner structure of the door is illustrated in more detail in Figures 6. Figure 6 schematically illustrates the inner structure of a door = 25 -1.1 ', which door is made of partly virgin and partly recycled materials. with the recycled part or recycled part blank, in the manufacture of a door made of partly virgin and partly recycled materials 1: 1 ', which is illustrated in Figure 6.'
    O N 30 In Figures 6 and 7, the same reference numerals are used for those parts derived from a door made of a virgin material (polyester resin, fiber reinforcement, filling material, and gelcoat outer layer 30).
    Fig. 7 schematically shows a recycling section 12. The recycling section 12 consists of a one-piece door plate body 10 having two parallel plate elements 101 and 102, the plate elements being positioned at opposite ends and spaced apart by means of a bridge element 103. In the recycled section 12, the body polyester matrix of the door panel 10 is a recycled fiber-reinforced polyester matrix4a (since the recycled section is previously made of a molded door panel) and lacks a majority of to the brief description above.
    Fig. 5 shows a schematic cross-sectional view of the internal structure of a door made of virgin materials 1: 1 '(reference embodiment). The door plate 10 of the door 1 comprises two parallel plate elements 101,102 spaced apart by the bridge element 103 during the molding. The inner layer 8 of the door plate 10, in which the inner layer 8 is filled with a filling material 80, remains in the space defined by the plate elements 101, 102 and the connecting bridge element 103. The plastic composite of each plate element 101 and 102 comprises a 4. A gelcoat outer layer 30 based on ethylene-unsaturated polyester resin is provided on the surface of said polyester matrix 4 during molding to impart chemical resistance to the door panel.
    The plate elements 101, 102 and said bridge element 103 are seamlessly connected to each other in a compression molding. As shown in Figs. 2 and 3B, the bridge element 103 is transverse to the direction of the plate elements 101, 102 and rotates the longitudinal and width ends of the plate elements 101, 102. »The thickness of the gelcoat outer layer 30 of the plate elements 101, 102 of the door plate 10 may be = e.g. 0.5 mm.
    N E The width of the inner part 8 of the door panel 10 in the transverse direction of the door panel can be about 40 mm. i The thickness of each fiber-reinforced polyester matrix 4 in the transverse direction of the door panel 10 = 30 can be about 2.5 mm. When the door 1 is made of virgin resin and fibers S, the mold pressing of the door is used as illustrated in Fig. 4. A gelcoat coating 3 made of polyester resin is applied to the surface of each mold part 71.72.
    a plurality of layers of fiber-reinforced resin 40 based on an ethylenically unsaturated polyester resin reinforced with a fibrous material are applied to the coating. With regard to the heating of the door molding and the implementation of the pressing, reference is made here to the general technique in the art. The filler material 80 shown in Figure 5 may be foamed polyurethane or a polyurea resin-based material used in place of polyurethane, one or more polyurethane sheets, one or more gypsum sheets, or barium sulfate-based gypsum board or vermiculite. Other inert fillers may also be possible. The impact resistance of the hard object on the surface 3 of the molded door leaf illustrated in Figures 1 and 5, tested in accordance with standard SFS-EN 950, shall be such that the diameter of the impact plate on the door leaf is not more than 1.5 mm and the average for depressions is not more than 1 mm. At a vertical load of 1000 N, the post-deflection of the door leaf 10 should not exceed 1.0 mm as determined by the test method according to SFS-EN-947. The post-deflection due to the torsional load of 350 N on the door leaf should be less than 2 mm, determined by the test method according to standard SFS-EN-948. In addition, the door leaf should have a resistance to chemicals and oxidizing agents — determined in accordance with EN 14688 for one or more of the following substances for at least two hours or at least 16 hours: acid such as acetic acid (10% v / v), base such as sodium hydroxide (5% w / v) m), an alcohol such as ethanol (70% v / v), a bleaching agent such as sodium hypochlorite, an oxidizing agent such as methylene blue (1% w / v) and an N salt such as sodium chloride (50% v / v)).
    NO 25 - Furthermore, the surface made of the gelcoat material of the door 1 should be resistant to cold liquids as determined according to DIN 68861 (SFS-EN 12720) for the following substances: coffee, mild detergent, cola drink, olive oil, paraffin oil, acetone, hydrochloride, milk, blood. The recycling part 12 according to the invention, on which the gelcoat outer layer S 30 - (glaze) is thus missing, is utilized for the production of a molded door. This is illustrated
    In particular in Figures 2 to 4, 6 to 8.
    The molded door is manufactured as follows (see Figure 8). As the mold 7, the mold shown in Fig. 4 is again used, which comprises two mold halves 7; 71.7; 72. The shape of each mold part is again adapted to produce the plate elements 101,102 and the bridge element 103 connecting them (step 100). A gelcoat coating 3 made of polyester resin is applied to the surface of each mold portion 71,72 (step 200). A few, often only one, fiber-reinforced resin layers 40 based on an ethylenically unsaturated polyester resin reinforced with a fibrous material are then laminated over the gelcoat coating 3 of each mold portion 71,72 (step 300).
    - Before the mold parts 71,72 are pressed against each other while heating, a recycling part 12 of the door plate 10 is inserted between the mold parts 71,72, comprising a main part of the fiber-reinforced polyester matrix 4a of the previously produced door plate 10; 11 but not the gelcoat outer layer 3 (step 400). The mold 7 is then closed by compressing said two mold parts 71,72 together while heating (500). With regard to the more precise implementation of the heating and pressing of the door molding, reference is again made here to the general technique in the art.
    The door panel 10 manufactured as described above thus comprises both a virgin plastic composite 4 and a recycled plastic composite from the recycling section 12, which is mainly a fiber-reinforced polyester matrix 4a and a filling material.
    80. The outer layer of gelcoat is removed from the polyester matrix 4a of the recycling section 12
    30. The recycling portion 12 of the door panel 10 generally comprises a major portion of a door panel 10 previously made, for example, by compression molding; 11 of the fiber-reinforced polyester matrix 4a.
    The recycled portion 12 utilized in the door compression molding described above, or the door panel 25 formed from the recycled portion 12, is schematically illustrated in a side cross-sectional view in Figure 7. The door panel 10 may either comprise a recycled portion 12 alone or a recycled portion blank. Such a door panel 10 includes an inner layer 8 with a filler material 80. The filler material 80 is surrounded by a fiber-reinforced polyester matrix 4a (recycled). The gelcoat outer layer is missing from the top of the polyester matrix 4a, i.e. the fiber-reinforced polyester matrix 4a forms the surface of the recycling section. Figure 6 shows a molded door 1 made as described above; 1 ", in the production of which N recycled part 12 is utilized. The inner layer 8, in which the one-piece recycling part 12 of the door plate is now placed in the inner layer 8 during the molding (cf. Fig. 7).
    As again shown in Figures 2 and 3B, the bridge element 103 is transverse to the direction of the plate elements 101, 102 and rotates the longitudinal and widthwise ends of the plate elements 101, 102.
    Each panel element 101 and 102 comprises a plastic composite made of a fiber-reinforced polyester matrix based on an ethylenically unsaturated polyester resin 4 which provides mechanical strength to the molded door panel 10. ethylenically unsaturated polyester resin. About 50 to 90% by weight of the fiber-reinforced polyester matrix 4 is derived from the recycled polyester matrix 4a, which is thus derived from a previously manufactured door panel 10; 11 (e.g., the door panel of the recycled portion 12 shown in Fig. 7), which lacks a gelcoat outer layer and thus forms a major portion of the fiber-reinforced polyester matrix 4. 10 to 50% by weight of the fiber-reinforced polyester matrix 4 is a virgin fiber-reinforced polyester matrix 40, is laminated on a cured gelcoat coating 3 applied over each mold half 71, 72. In a preferred embodiment of the invention, about 90% by weight of the fiber-reinforced polyester matrix 4 comprises recycled fiber-reinforced polyester matrix 4a and 10% by weight is derived from a previously made door and comprises a layer of new virgin fiber-reinforced polyester matrix 40.
    The thickness of the fiber-reinforced polyester resin layer I to be laminated to each mold half 71.72 is only a fraction of what it would be if the fiber-reinforced polyester resin matrix (layer) 4 were used to form the fiber-reinforced polyester resin matrix (layer):
    LO N 30 - The thickness 30 of the gelcoat outer layer N of the plate elements 101, 102 of the door plate 10 containing the recycled part 12 is, for example, 0.5 mm. The width of the inner part 8 of the door plate 10 in the transverse direction of the door plate is about 40 mm. The thickness of the fiber-reinforced polyester matrix layer 4 (4a + 40a) of each panel element 101, 102 in the transverse direction of the door panel 10 is about 2.5 mm. In a preferred embodiment of the invention, the fiber-reinforced polyester matrix layer 4 (4a +40) based on the ethylenically unsaturated polyester resin of the plastic composite contains glass fiber. The door 1 with the recycled part 12 should also meet the same requirements as a molded door made of virgin material: average for depressions up to 1 mm. At a vertical load of 1000 N, the post-deflection of the door leaf should not exceed 1.0 mm as determined by the test method according to SFS-EN-947. The post-deflection due to the torsional load of 350 N on the door leaf should be less than 2 mm, determined by the test method according to standard SFS-EN-948. When the door plate 10 of the door 1 is made of a one-piece recycled part 12, (cf. Fig. 7), this recycled part 12 should generally be made of a previously made door plate 10; 11 from the recycled blank 12a (cf. Figs. 2, 3A and 3B)) to make it suitable for the production of a torsionally strong and hard-hardened door 1. Fig. 2, 3A-3B illustrates the preparation of the blank 12a of the recycling portion 12 of the door 1. Generally speaking, the blank of the recycled section is made of a previously manufactured door panel 10; from which the fittings 5 and the window and the outer layer of the gelcoat are removed. The door plate thus obtained is used as a blank 12a of the recycling section 12. The blank 12a of the recycling section comprises a door plate 10 thus recycled; 11, which does not have a gelcoat outer layer and has N 25 window openings 2 or fittings 6 from which the windows or fittings have been removed, respectively. © perdis previously, for example a molded door plate 10; 11 = from window openings or fittings, further processed to provide a recycled portion 12 N of the door panel 10.
    N - Fill pieces 45 and possibly an adhesive used for gluing the filler pieces are fitted to the window openings 2 and the fitting openings 6 of the recycled part blank 12a. This gives a one-piece recycle section 12, of which the gelcoat outer surface 3; 30 is removed and comprises the filler pieces 45 and optionally an adhesive used to glue the filler pieces.
    The recycled blank 12a of the recycled door panel 10; 11 shown in Figure 2 is made by removing both the gelcoat outer layer 30 and the window from the previously manufactured door panel.
    In this case, a blank 12a of the recycling part is obtained, which has a window opening 2 shown in Fig. 2. In addition, the blank 12a of the recycling part shown in Fig. 2 has a plurality of fitting openings 6; 6a, 6b (lock opening 6a, button opening 6b and puller opening 6b), wherein each fitting opening 6a and 6b is formed by removing a previously molded door plate 10; 11 fitting 5. Fitting 5 is selected from - a set comprising a door button 5; 52, hinge 5; 51, puller and lock 5; 53. Fig. 3A shows a blank 12a of a recycled portion having a window opening 2 made by removing a previously manufactured door panel 10; 11 window openings 2 blank window.
    The gelcoat outer layer 3 (glaze) is being removed from the surface of the door panel 10;
    Fig. 3B shows how a filling piece 45 is installed in the window opening 2 of the blank 12a of the recycling section 12 according to Fig. 2.
    The preform 12 of the recycled part 12a of the door plate 10 is a previously produced door plate 10; 11, in which a window opening is formed and the gelcoat outer layer is removed.
    The door leaf 10, 11, in turn, may itself be made of a virgin plastic composite or, alternatively, may contain material from another, previously made recycled part of the door leaf. - The filling pieces 45 can thus be either filling pieces 45 made of O 25 material removed from the openings 2, 6 in the door plate 10 or separately made filling pieces 45. & The filling piece 45 comprises a fiber-reinforced polyester matrix based on an ethylenically unsaturated polyester resin.
    Preferably, however, the filler pieces 45 comprise a fibrous polyester matrix based on an ethylenically unsaturated polyester resin removed from the openings 2, © 6 of the recycled door panel 10, 11.
    S Application example 1 The resistance of chemicals and oxidizing substances in the door panel contained in recycled section 12 was determined according to the method according to SFS-EN 14688, clause 5.5.1.1 '. to a humidity of 50% + 5%. The chemicals and oxidizing agents were as follows: Acid: acetic acid, CH3COOH (10% v / v), Base: sodium hydroxide, NaOH (5% (w / v) Alcohol: ethanol C2H5OH (70% v / v) Bleach: Sodium hypochlorite NaOCl, 5% active chlorine (Cl2) Oxidizing agent: methylene blue (1% w / w) Salt: Sodium chloride, NaCl 170 g / l diluted to 50%.
    At the end of the test (2 hours after exposure to the surface of the door panel), no significant traces of chemicals or oxidizing agents were visible on the washed and dried surface of the door panel. After 16 hours, only NaOH had left a reasonable mark and the stain caused by the methylene oil had disappeared. Application example 2 The resistance of the surface of a fiberglass-reinforced door panel contained in the recycled part to discoloration caused by cold liquids and other damage specified in SFS-EN 14688 was determined according to DIN 68861 (SFS-EN 12720). after reaching a temperature of 23 + - 2 degrees and a relative humidity of 50% + 5 S% for 24 hours. <
    N I Cold liquid Trace left on the surface of the door leaf as = 1-5 00
    N LO 25 1. Coffee 5 a N 2. Detergent (Serto) 5
    3. Cola drink (Coca Cola) 5
    4. Ink pen (waterproof) 1
    5. Detergent (Fairy) 5
    6. Olive oil 5
    7. Paraffin oil 5 28 Acetone 4
    9. Hydrochloride or hydrochloric acid (HCl) 3
    10.Milk 5
    11. Animal blood (livestock) 5
    12. Chlorine 5 - Surface changes (discoloration, etc.) in visual inspection: 1 Strong change, 2 significant change, 3 moderate change; 4: small change; 5: no changes. The door panels thus withstood well all normal household liquids and beverages in daily use. Application Example 3 - The resistance of chemicals and oxidizing agents in the glass-reinforced door panel contained in the recycled section 12 was determined by the method according to SFS-EN 14688, clause 5.5.1.1 '. relative humidity 50% + 5%. The chemicals and oxidizing agents were as follows:
    N N 20 - Acid: acetic acid, CH 3 COOH (10% v / v), O
    O Base: sodium hydroxide, NaOH (5% (w / w)) Alcohol: ethanol C2H5OH (70% v / v) Bleach: Sodium hypochlorite NaOCl, 5% active chlorine (Cl2)
    LO S Oxidizing agent: methylene blue (1% w / w) - Salt: Sodium chloride, NaCl 170 g / l diluted to 50%.
    At the end of the test (2 hours after exposure to the surface of the door panel), a slight trace of methylene blue remained and no significant traces of other chemicals and oxidizing agents were visible on the washed and dried surface of the door panel consisting only of the recycled portion. After 16 hours, the stain caused by a methylene blue was almost gone.
    Application example 4 The resistance of the surface of the recycled part to discoloration due to cold liquids and other damage specified in SFS-EN 14688 was determined by the method according to DIN 68861 (SFS-EN 12720). degree and relative humidity 50% + 5%. Cold liquid Traces left on the surface of the door panel in scale 1-5
    1. Coffee 5
    2. Detergent (Omo) 5
    3. Cola drink (Coca Cola) 5
    4. Ink pen (waterproof) 1
    5. Cleaner (Fairy) 3
    6. Olive oil 3 N 20 7. Paraffin oil 5
    N S 8. Acetone 4
    N _ 9. Hydrochloric acid (HCl) 3 a © 10.Milk 5 3
    MN 2 11. Animal blood (livestock) 4 IS .
    12. Chlorine 5
    Surface changes (discoloration, etc.) in visual inspection: 1 Strong change, 2 significant change, 3 moderate change; 4: small change; 5: no changes. The uncoated door panels thus only withstood all normal household liquids and beverages in daily use.
    This is probably due to the fact that the fiber-reinforced polyester surface is considerably rougher than the gelcoat surface and thus easily collects dirt and dust. As such, the recycled part 12 cannot be used as a door leaf, but must be coated with an outer layer of gelcoat, which makes the surface of the door leaf sufficiently smooth. OF O OF
    O <Q + OF
    I a a 00 <r OF LO OF O OF
    Reference number list 1 Door 10 door panel 11 recycled door panel 12 recycling section 12a recycling section blank 101 panel element 102 panel element 103 bridge element 20 frame 2 Window opening 3 Gelcoat coating (in mold) 30 Gelcoat outer layer (door panel coating) 4 Fiber-reinforced polyester polyester resin matrix (recycled) O 40 Fiber-reinforced polyester matrix (of virgin material) <QN 45 Filling piece
    I a = 20 5 Hela 00
    N 0 51 hinge OF
    O N 52 button 53 lock
    6 Fitting opening 6a locking housing opening 6b press opening 7 Mold 71 mold part (mold half) 72 mold part (mold half) 8 Inner layer 80 Filling material 9 Abrasive 100, 200, 300, 400, -500 method steps OF O OF
    O <Q < OF
    I = 00 <r OF LO OF O OF
    权利要求:
    Claims (45)
    [1]
    A recycling section (12) for making a polyester resin-based fiber-reinforced door (1), the fiber-reinforced door (1) comprising a body of a sandwich door panel (10) made by molding a virgin plastic composite and a recycled section (12) and each door panel. ) the frame consists of a fiber-reinforced polyester matrix (4) based on an ethylenically unsaturated polyester resin providing mechanical resistance to the door panel (10), and a chemical resistance to the door panel ( ethylene-unsaturated polyester resin, the gelcoat outer layer (30) of which has been allowed to cure in a mold before said fiber-reinforced polyester matrix is arranged on said gelcoat outer layer, and which door panel (10) body comprises two parallel bridge elements ) field a seamlessly positioned plate element (101,102) so that a space defined by said frame plate elements (101,102) and the bridge element (103) arranged to connect them leaves a hollow inner layer (8) of the door plate (10) in which the inner layer (8) an optional filling material can be placed in which the bridge element (103) is transverse to the plate elements (101,102) and rotates the longitudinal and transverse ends of the plate elements (101, 102), the mold resistance of the molded door frame that the diameter of the impact plate on the door leaf frame is not more than 1.5 mm and the average for the depressions is not more than 1 mm. - characterized in that the recirculation part (12) comprises a body of a one-piece door leaf (10), O 25 - having two parallel plate elements (101) spaced apart by means of a bridge element (103; 103 ', 103 "). 102) and wherein + in the recycling section (12) the body of the door panel (10) is made of a fiber-reinforced polyester matrix (4) which is free of the major part of the gelcoat outer layer (30), preferably = the entire gelcoat outer layer (30). Recycled part according to Claim 1, characterized in that the outer layer (30) of the gelcoat is absent from the top of the recycled part (4) to such an extent that it does not meet the resistance of chemicals and oxidizing agents to one or more of the following according to SFS-EN 14688 for substances with a test time of at least two hours or at least 16 hours: an acid such as acetic acid (10% v / v),
    [2]
    a base such as sodium hydroxide (5% (w / v)), an alcohol such as ethanol (70% v / v), a bleaching agent such as sodium hypochlorite, an oxidizing agent such as methylene blue (1% w / v) and a salt such as sodium chloride (50% v / v) )).
    [3]
    Recycled part according to Claim 1, characterized in that the gelcoat outer layer (3) is missing from the top of the recycled part (12), the surface of the door leaf not satisfying the resistance of cold liquids, but the cold liquid causing at least a moderate change in accordance with DIN 68861 (SFS-EN 12720) for three or more of the following substances with a test time of 2 or 16 hours: coffee, mild detergent, cola drink, ink (water-resistant), - olive oil, paraffin oil, acetone, hydrogen chloride, milk, animal ( cattle) blood.
    [4]
    Recycled part according to Claim 1, characterized in that the polyester resin-based fiber-reinforced door (1) is resistant to chemicals and oxidizing agents, tested in accordance with EN 14688 (SFS-EN 12720) for at least two hours or at least 16 hours: acid such as acetic acid (10% v / v), base such as sodium hydroxide (5% (w / v)), alcohol such as ethanol (70% v / v), bleach such as sodium hypochlorite, oxidizing agent such as methylene blue (1% w / v) m) and a salt such as sodium chloride (50% v / v)).
    [5]
    Recycled part according to Claim 1, characterized in that the surface of the polyester resin-based fiber-reinforced door (1) is resistant to cold liquids - determined in accordance with DIN 68861 (SFS-EN 12720) for the following substances: coffee, mild detergent, cola drink, olive oil , paraffin oil, acetone, hydrochloride, milk, bovine blood, resulting in no more than a small change (4) in the visual inspection of the door surface from acetone and a moderate change (3) from hydrochloric acid. -
    [6]
    The recyclable part (12) according to claim 1, characterized in that it further comprises a hollow inner layer (8) inside the body made of a fiber-reinforced polyester matrix with a filling material (80). OF
    [7]
    Recycling section (12) according to claim 1, characterized in that a filling material (80) selected from the group consisting of a polyurea resin-based material, a polyurethane sheet, a foamed polyurethane, a gypsum board, is added to the hollow inner layer (8) of the door. barium sulphate based gypsum board and vermiculite O
    [8]
    The door panel recycling part (12) according to claim 1, characterized in that the recycling part (12) comprises filling pieces (45) and optionally an adhesive used for gluing the filling pieces (45), the recycling part (12) being made by fitting the filling pieces (45). the recycled part used in the manufacture of the recycling part (12)
    (12) to the openings in the blank, which filler pieces (45) are either filler pieces (45) removed from the door panel (10) or separately made filler pieces (45).
    [9]
    Recycling section (12) according to claim 8, characterized in that the filling pieces (45) comprise a fiber-reinforced polyester matrix based on an ethylenically unsaturated polyester resin.
    [10]
    Door panel recycling section (12) according to claim 1 or 8, characterized in that the recycling section (12) is made of a blank of the door panel recycling section comprising a door panel (11) having a window opening (2) by removing the window from the opening blank.
    [11]
    Door panel recycling section (12) according to claim 1 or 8, characterized in that the recycling section (12) is made of a blank of the door panel recycling section comprising a door panel (11) having at least one fitting opening (6), said fitting opening (6) is formed by removing material from the door panel (11) around the fitting (5).
    [12]
    A door panel recycling section (12) according to claim 11, characterized in that the fitting (5) is selected from the group consisting of a door button (52), a puller and a lock (53).
    [13]
    Recycling section (12) according to claim 1, characterized in that the blank (12a) of the recycling section (12) of the door panel (10) has at least one opening which is a window opening formed when the window ( 2) or the fitting opening (6) when the fitting (5) has been removed from the recycled door leaf frame.
    [14]
    Recycling section (12) according to claim 1, characterized in that the gelcoat outer layer (30) of the N door (1) is made of a liquid gelcoat composition comprising a gelcoat resin and at least one solvent monomer and an excipient. dythia.
    [15]
    Recycling section (12) according to claim 14, characterized in that = the gelcoat composition from which the gelcoat outer layer (30) is made comprises 30-60% gelcoat resin, 0-30% pigment, preferably 5-30% pigment and 10-50% solvent, preferably 20-40% solvent and 0.1 -3% accelerator.
    [16]
    Recycling section (12) according to Claim 15, characterized in that the solvent is a monomeric hardener which is capable of crosslinking the polyester resin.
    [17]
    A recycler (12) according to claim 16, characterized in that the solvent comprises a monomer selected from the group consisting of acrylate monomer, styrene, vinyl, toluene, C-methylstyrene, divinylbenzene, dialyl phthalate, and triallyl cyanorate.
    [18]
    Recycling section (12) according to claim 15, characterized in that the liquid gelcoat composition further contains dispersants, antifoams, UV light inhibitors, thixotropic agents.
    [19]
    Recycling section (12) according to claim 15, characterized in that the liquid gelcoat composition comprises an accelerator which is an organic peroxide or peracid.
    [20]
    Recycling section (12) according to claim 15, characterized in that the liquid gelcoat composition comprises an unsaturated polyester resin which is a polyester resin based on isophthalic acid, and a hardener which cures said resin upon heating, and a pigment.
    [21]
    Recycling section (12) according to claim 1, characterized in that the door panel (10) comprises an outer layer (30) of gelcoat with a thickness of 0.5 mm and a glass-fiber-reinforced laminate layer based on a glass-fiber-reinforced polyester matrix based on an ethylenically unsaturated polyester resin. 4.40) with a thickness of 2 to 5 mm, with a vertical load deflection of the door leaf of 1000 N - up to 1.0 mm as determined by the test method according to SFS-EN-947.
    [22]
    Recycling section (12) according to Claim 1, characterized in that the post-deflection caused by the torsional load 350 N of the door leaf (10) is less than 2 mm, determined by a test method in accordance with standard SFS-EN-948.
    [23]
    NS 25 Recycling section (12) according to Claim 1, characterized in that the fiber-reinforced polyester matrix I (4) based on the ethylenically unsaturated polyester resin of the body of the door plate (10) is formed by reacting at least one ethylenically unsaturated dicarboxylic acid or its acid anhydride and a mixture of saturated dicarboxylic acid = reacting with at least one polyol, wherein the ethylenically unsaturated dicarboxylic acid or an acid anhydride thereof is preferably selected from the group consisting of: maleic acid, maleic anhydride, fumaric acid, itaconic acid, phthalic acid, phthalic acid, phthalic acid, phthalic acid methyldinedin anhydride, hexahydrophthalic anhydride, dimethyl terephthalate, recycled terephthalate.
    [24]
    The recycled part (12) according to claim 1, characterized in that the plastic composite made of the virgin plastic composite and the recycled part (12) comprises a fiber-reinforced polyester matrix (40) with a gelcoat outer layer (30) formed of the virgin polyester resin.
    [25]
    Recycled part (12) according to claim 24, characterized in that about 50 to 90% by weight of the fiber-reinforced polyester matrix comprises a recycled fiber-reinforced polyester matrix (4) and 10 to 50% by weight of the fiber-reinforced polyester matrix, and - comprises a virgin fiber-reinforced polyester matrix (40). ).
    [26]
    Recycled section (12) according to claim 24, characterized in that about 90% by weight of the fiber-reinforced polyester matrix comprises a recycled fiber-reinforced polyester matrix (4) and 10% by weight comprises a virgin fiber-reinforced polyester matrix (40).
    [27]
    Recycled section (12) according to Claim 1, characterized in that the door panel (10) made of plastic composite, on which the outer layer (30) of gelcoat is applied, is airtight and watertight.
    [28]
    Recycling section (12) according to claim 1, characterized in that the thickness of the gelcoat outer layer (30) in the transverse direction of the door panel is 0.5 mm and the thickness of the fiber-reinforced polyester matrix in the transverse direction of the door panel is 2.5 mm.
    [29]
    Recycling section (12) according to Claim 1, characterized in that the fiber-reinforced polyester matrix (4, 40) of the plastic composite based on an ethylenically unsaturated polyester resin contains glass fiber.
    N O
    [30]
    Recycling section (12) according to Claim 1, characterized in that
    O + 25 - that the glass fiber-reinforced laminate layer of the door panel (10) has a thickness of 2 -3 mm and is formed of a crosslinkable (curable) = polyester resin and fiber reinforcement, in particular glass fiber, under the influence of heat and hardener. 00 =
    [31]
    Recycling part (12) according to Claim 1, characterized in that the width of the inner part (8) of the N door plate (10) in the transverse direction of the door plate is approximately 40 mm.
    O
    OF
    [32]
    The recirculating part (12) according to claim 1, characterized in that the door further comprises a frame (20) surrounding the door opening into which the door plate (10) of the door (1) can be fitted via hinges (5; 51) or a sliding rail extending in the width direction of the door opening. (1) the door leaf (10) is adjustable by means of a roller or similar sliding part,
    [33]
    Polyester resin-based fiber-reinforced door (1) comprising a recyclable part (12) according to one of the preceding claims, characterized in that the door (1) - comprises a body of a sandwich-shaped door leaf (10) made of a molded plastic composite , providing a gelcoat coating (3) on the inner surface of the two different mold halves (71,72) of the mold (7), allowing these gelcoat coatings (3) to cure and laminating one or more fiber-reinforced polyester matrix layers over said cured gelcoat coatings (3) and a one-piece recycling portion (12) made of a fiber-reinforced polyester matrix body (4) based on an unsaturated polyester resin by arranging a recycling portion (12) between said fiber-reinforced polyester matrix layers (s). cured gelcoat coatings arranged on the inner surface en (3) on and closing the mold.
    [34]
    A polyester resin-based fiber-reinforced door (1) comprising a body of a sandwich door panel (10) made of a compression molded virgin plastic composite and a recycled portion (12), the body of the door panel (10) being comprised of a resilient door panel (10) , a fiber-reinforced polyester matrix (4) based on an ethylenically unsaturated polyester resin, and a gelcoat outer layer (30) which can be provided on said fiber-reinforced polyester matrix during molding to provide a chemical resistance to the door panel, allowed to cure in a mold, before said fiber-reinforced polyester matrix is arranged on said gelcoat outer layer, N and each door leaf body (10) comprises two parallel, seamlessly spaced plate members (101,102) that a hollow inner layer (8) of the door leaf N (10) remains in the space between said frame plate elements (101,102) and the bridge element (103) arranged at the ends, in which an optional S filling material can be placed in the inner layer (8). the bridge element (103) is transverse to the direction of the plate elements (101,102) and rotates the longitudinal and widthwise ends of both plate elements (101, 102),
    wherein the impact resistance of the hard object of the molded door leaf frame, tested according to standard SFS-EN 950, is such that the diameter of the impact on the door leaf frame is not more than 1.5 mm and the average for the depressions is not more than 1 mm. characterized in that the fiber-reinforced door is manufactured using a recirculating part (12) comprising - a body of a one-piece door leaf (10) having two parallel plate elements (101) spaced apart by means of a bridge element (103; 103) ; 101 ', 102; 102 ") and the frame of the door panel (10) of the recycled part (12) is made of a fiber-reinforced polyester matrix (4), the top of which is missing the main part of the gelcoat outer layer (30).
    [35]
    A method of manufacturing a polyester resin-based, fiber-reinforced, molded door (1) having a recycled portion as defined in claim 1, characterized in that the door (1) is manufactured by: -forming two mold parts (mold halves) (7; 71.7; 72), for which each plate element (101,102) and the bridge element (s) 103 connecting them are adapted to be produced - by applying a gelcoat coating (3) made of polyester resin to the surface of both mold parts (71,72), - by laminating each mold part (71,72) at least one fiber-reinforced resin layer (40) based on an ethylenically unsaturated polyester resin reinforced with a fibrous material on the cured gelcoat coating (3), by placing between the mold parts (71,72), in particular between the fiber-reinforced polyester matrix layers (40), which polyester matrix layers (40) are laminated to the inner surface of the mold parts (71,72). on top of the hardened gelcoat coatings (3), a recycling section (12) comprising a single 25-piece door leaf body (10) having two parallel plate elements I () spaced apart by a bridge element 101,102) and each frame of the door panel (10) of the recycled part (4) is made of a fiber-reinforced - polyester matrix (4) and lacks a gelcoat coating (30), 00 + Lo - by closing the mold (7), pressing said two mold parts (71,72) together with S 30 - while heating.
    OF
    [36]
    A method according to claim 35, characterized in that the gelcoat outer layer (30) is missing from the surface of the recycle part (12), wherein the surface of the recycle part (12) does not meet the resistance of cold liquids but causes at least a moderate change in the surface of the body. determined in accordance with DIN 68861 (SFS-EN 12720) for three or more of the following substances with a test time of 2 or 16 hours: coffee, mild detergent, cola drink, ink (water-resistant), olive oil, paraffin oil, acetone, hydrogen chloride, milk, animal blood.
    [37]
    A method according to claim 36, characterized in that the recycling part (12) of the door plate (10) comprises a door plate (11) from which the gelcoat outer layer (30) has been removed and which recycling part (12) comprises a substantial part of the finished door plate (1). - the fiber-reinforced polyester resin matrix required for the production.
    [38]
    A method according to claim 35, characterized in that the recycle part (12) further comprises an inner layer (8) containing a filling material,
    [39]
    A process according to claim 35, characterized in that the polyester resin used to prepare the polyester matrix is formed by reacting at least one ethylenically unsaturated dicarboxylic acid or an acid anhydride or a mixture of an unsaturated dicarboxylic acid and a saturated dicarboxylic acid with at least one polyol.
    [40]
    The method of claim 39, wherein the ethylenically unsaturated dicarboxylic acid or acid anhydride thereof is selected from the group consisting of: maleic acid, maleic anhydride, fumaric acid, itaconic acid, phthalic anhydride, phthalic anhydride, isophthalic acid, tereic acid, terephthalic acid anhydride, hexahydrophthalic anhydride, dimethyl terephthalate, recycled terephthalate.
    [41]
    41. The method of claim 39, wherein the S polyol is selected from the group consisting of glycols such as ethylene glycol, propylene glycol; diols such as 1,3-propanediol, 1,4-propanediol, 1,4-butanediol, 2,2-methyl- [1,3-propanediol, 2-methyl-1,3-propanediol; glycol ethers; and triols such as glycerol N and trimethylpropane.
    [42]
    I a = 42. Process according to one of Claims 35 to 41, characterized in that the polyester resin = 30 used for the preparation of the fiber-reinforced polyester matrix is formed by reacting phthalic acid or its anhydride with a suitable polyol S.
    [43]
    Process according to one of Claims 35 to 42, characterized in that the polyester resin used for the production of the gelcoat outer layer (30) is formed by reacting isophthalic acid or its anhydride with a suitable polyol.
    [44]
    A method according to claim 43, characterized in that the polyester matrix of the door panel and / or the gelcoat outer layer on top of the polyester matrix is - made of a polyester resin containing an unsaturated polyester further comprising a reactive monomer (solvent) such as styrene and an accelerator and possible metal catalyst such as catalyst.
    [45]
    Use of a recycling section (12) in the manufacture of a polyester resin-based fiber-reinforced door (1), wherein the fiber-reinforced door (1) is molded and the recycling section (12) comprises a body of a one-piece door panel (10) spaced apart by two bridge members , opposite, a positioned plate element (101,102) and in which the body of the door plate (10,11) is made of a fiber-reinforced polyester matrix (4) in the recycling section (12).
    OF
    O
    OF
    O <Q +
    OF
    I a a 00 +
    OF
    LO
    OF
    O
    OF
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    同族专利:
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    EP3929247A2|2021-12-29|
    FI20205669A1|2021-12-25|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
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    优先权:
    申请号 | 申请日 | 专利标题
    FI20205669A|FI20205669A1|2020-06-24|2020-06-24|Polyester resin-based fibre reinforced door and method of manufacturing thereof|
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