Patent FR-2951399-A1 (FR)
Title: Fabricating sealed composite panel, comprises preparing first lower mold component comprising relief matching structure, filling with gel coat inside first lower mold component, and depositing glass reinforcement and resin on the gel coat
Inventor: RONGIER FABRICE
IPC: B29C70/02
Filed: 2009-10-16
Abstract: The process of fabricating a sealed composite panel (1), comprises preparing a first lower mold component comprising a relief matching structure with juxtaposition of wooden planks on its inner face, filling with a gel coat inside the first lower mold component, depositing, on the gel coat, a glass reinforcement and a resin, which divides the resin by impregnating the glass reinforcement for forming a first layer for constituting a first side flange (2), and laying a second layer on the first layer for filling the interior of the first mold component. The process of fabricating a sealed composite panel (1), comprises preparing a first lower mold component comprising a relief matching structure with juxtaposition of wooden planks on its inner face, filling with a gel coat inside the first lower mold component, depositing, on the gel coat, a glass reinforcement and a resin, which divides the resin by impregnating the glass reinforcement for forming a first layer for constituting a first side flange (2), laying a second layer on the first layer for filling the interior of the first mold component, extending the layer along a longitudinal direction to contact longitudinal edges and then extending along their greater surface area parallel to the inner face and at the junction of two adjacent plates of the first plate and the second plate, inserting a reinforcement strip (6) in one part between the first layer and a first side of lower side of the adjacent plates and then between the longitudinal edges of adjacent plates and other part tacked on a second side of the upper side of one of the adjacent sheets, which are opposite to the first layer, depositing, on the upper surface of the second layer, a third layer constituted of glass reinforcement, resin and a second side flange (3), dividing the resin by impregnating the glass reinforcement, laying, on the third layer, a second upper mold component to fit together as complementary to the first lower mold component, pressing the assembly constituted by the second upper component and the first lower component for carrying out the creeping of the resin through the glass reinforcement and extracting air bubbles, and carrying out the polymerization of the resin according to its specifications. The second layer is constituted of sheets of insulating foam such as polyurethane sealed against each other in the first lower mold component. The step of inserting the reinforcement strip is performed for constituting a reinforcement profile of U and Z shapes. The cross surfaces are superimposed by insulating foam sheets adjacent of which entire or part comprises reinforcing strips at their junction extending in a direction perpendicular to the longitudinal direction for constituting an intermediate layer between the second layer and the third layer. The process further comprises demolding the composite panel, after complete polymerization of the resin, cutting the panel into desired size, removing by machining on some of its visible edges on a depth of some millimeters up to a specified surface, filling the space between the surface and the ends of the flanges with a layer of peripheral sealing layer constituted by a conformation by glass fiber reinforced polyester adhesive occupying the space released by machining to form a defined edge of the panel, and smoothing the edge of the panel. The smoothing the edge of the panel is performed with a tool providing the appearance of the wood plank structure to the defined edge. An independent claim is included for a sealed composite panel.