Fiber-reinforced composites and building structures comprising fiber-reinforced composites
The present invention provides fiber-reinforced composites, and components for buildings, such as door skins, that include fiber-reinforced composites. Also provided are methods and systems for manufacturing fiber-reinforced composites that may be used in building structures. In an embodiment, the present invention provides a fiber-reinforced composite comprising long fibers of fiberglass and polyurethane produced using long-fiber injection (LFI) technology.
1 . A fiber-reinforced composite building structure comprising a fiber and a polymer resin.
2 . The building structure of claim 1 , wherein the polymer resin comprises a thermosetting polymer.
3 . The building structure of claim 2 , wherein the thermosetting polymer comprises polyurethane.
4 . The building structure of claim 1 , wherein the fiber comprises fiberglass.
5 . The building structure of claim 1 , wherein the fiber ranges in length from about 5 mm to about 100 mm.
6 . The building structure of claim 1 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
7 . The building structure of claim 1 , further comprising a non-fiber filler.
8 . The building structure of claim 1 , further comprising a coloring agent.
9 . The building structure of claim 1 , further comprising at least one of a release agent, a barrier coat, or an in-mold coating applied to at least a portion of the structure.
10 . The building structure of claim 1 , further comprising a substantially planar structure.
11 . The building structure of claim 10 , wherein the structure comprises a door skin.
12 . The building structure of claim 10 , wherein the structure comprises a panel.
13 . The building structure of claim 1 , wherein the structure comprises cladding.
14 . The building structure of claim 1 , wherein the structure comprises a door frame or a portion of a door frame.
15 . The building structure of claim 1 , wherein the structure comprises a window frame part or a window part.
16 . The building structure of claim 1 , wherein the structure comprises siding.
17 . The building structure of claim 1 , wherein the structure comprises a shutter.
18 . The building structure of claim 1 , wherein the structure comprises a shingle.
19 . A fiber-reinforced composite door skin comprising a fiber and a polymer resin.
20 . The door skin of claim 19 , wherein the polymer resin comprises a thermosetting polymer.
21 . The door skin of claim 20 , wherein the thermosetting polymer comprises polyurethane.
22 . The door skin of claim 19 , wherein the fiber comprises fiberglass.
23 . The door skin of claim 19 , wherein the fiber ranges in length from about 5 mm to about 100 mm.
24 . The door skin of claim 19 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
25 . The door skin of claim 19 , further comprising a non-fiber filler.
26 . The door skin of claim 19 , further comprising a coloring agent.
27 . The door skin of claim 19 , further comprising at least one of a release agent, a barrier coat, or an in-mold coating applied to at least a portion of the structure.
28 . The door skin of claim 19 , further comprising a flat profile.
29 . The door skin of claim 19 , further comprising a molding.
30 . The door skin of claim 19 , further comprising an opening for a translucent panel.
31 . The door skin of claim 19 , further comprising a substantially smooth surface.
32 . The door skin of claim 19 , further comprising a grain pattern on at least one surface.
33 . A door comprising the door skin of claim 19 .
34 . A door comprising a fiber and a polymer resin formulated as a fiber-reinforced composite.
35 . The door of claim 34 , wherein the polymer resin comprises a thermosetting polymer.
36 . The door of claim 34 , wherein the thermosetting polymer comprises polyurethane.
37 . The door of claim 34 , wherein the fiber comprises fiberglass.
38 . The door of claim 34 , wherein the fiber ranges in length from about 5 mm to about 100 mm.
39 . The door of claim 34 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
40 . The door of claim 34 , further comprising a non-fiber filler.
41 . The door of claim 34 , further comprising a coloring agent.
42 . The door of claim 34 , further comprising at least one of a release agent, a barrier coat, or an in-mold coating applied to at least a portion of the structure.
43 . The door of claim 34 , wherein the fiber-reinforced composite comprises a door skin.
44 . The door of claim 34 , wherein the fiber-reinforced composite comprises a door panel.
45 . The door of claim 34 , wherein the fiber-reinforced composite comprises a plant-on structure.
46 . The door of claim 34 , wherein the fiber-reinforced composite comprises a cladding.
47 . The door of claim 34 , wherein the fiber-reinforced composite comprises an opening for a translucent panel.
48 . The door of claim 34 , wherein the fiber-reinforced composite comprises at least one substantially smooth surface.
49 . The door of claim 34 , wherein the fiber-reinforced composite comprises a grain pattern on at least one surface.
50 . A method for producing a building structure comprising the steps of:
preparing a mold having an internal volume in the shape a building structure;
dispensing a mixture comprising a plurality of fibers and a polymer resin onto a surface of the mold; and
allowing the resin to polymerize under conditions sufficient to produce a fiber-reinforced composite.
51 . The method of claim 50 , wherein the polymer resin comprises a thermosetting polymer.
52 . The method of claim 51 , wherein the thermosetting polymer comprises polyurethane.
53 . The method of claim 50 , wherein the fiber comprises fiberglass.
54 . The method of claim 50 , wherein the fiber ranges in length from about 5 mm to about 100 mm.
55 . The method of claim 50 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
56 . The method of claim 50 , further comprising applying a surface-active agent to at least a portion of the mixture dispersed onto the mold.
57 . The method of claim 56 , wherein the surface-active agent comprises at least one of a release agent or a barrier coating.
58 . The method of claim 50 , further comprising applying a surface-active agent to least one surface of the mold.
59 . The method of claim 58 , wherein the surface-active agent comprises at least one of a release agent, an in-mold coating or a barrier coating.
60 . The method of claim 50 , wherein the mold is shaped to form a substantially planar composite.
61 . The method of claim 60 , wherein the building structure comprises a door skin.
62 . The method of claim 60 , wherein the building structure comprises a panel.
63 . The method of claim 50 , wherein the building structure comprises cladding.
64 . The method of claim 50 , wherein the building structure comprises a door frame or a portion of a door frame.
65 . The method of claim 50 , wherein the building structure comprises a window frame part or a window part.
66 . The method of claim 50 , wherein the building structure comprises siding.
67 . The method of claim 50 , wherein the building structure comprises a shutter.
68 . The method of claim 50 , wherein the building structure comprises a shingle.
69 . A method for producing a door skin comprising the steps of:
preparing a mold comprising a first and second die, where both dies comprise at least one substantially planar surface;
dispensing a mixture comprising a plurality of fibers and a polymer resin onto the substantially planar surface of the first die;
bringing the substantially planar surface of the second die in contact with the fibers and resin; and
allowing the resin to polymerize under conditions sufficient to produce a fiber-reinforced composite in the shape of a door skin.
70 . The method of claim 69 , wherein the polymer resin comprises a thermosetting polymer.
71 . The method of claim 70 , wherein the thermosetting polymer comprises polyurethane.
72 . The method of claim 69 , wherein the fiber comprises fiberglass.
73 . The method of claim 69 , wherein the fiber ranges in length from about 5 mm to about 100 mm.
74 . The method of claim 69 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
75 . The method of claim 69 , further comprising applying a surface-active agent to at least a portion of the mixture dispensed onto the mold.
76 . The method of claim 75 , wherein the surface-active agent comprises a release agent or a barrier coating.
77 . The method of claim 69 , further comprising applying a surface-active agent to least one surface of the mold.
78 . The method of claim 77 , wherein the surface-active agent comprises at least one of a release agent, an in-mold coating or a barrier coating.
79 . The method of claim 69 , wherein at least one of the die surfaces in contact with the fibers and the polymer resin comprises a substantially flat surface such that the fiber-reinforced composite door skin comprises a flat profile.
80 . The method of claim 69 , wherein at least one of the die surfaces in contact with the fibers and the polymer resin comprises at least one of a groove or a protrusion such that the fiber-reinforced composite door skin comprises a molding.
81 . The method of claim 69 , wherein at least one of the die surfaces in contact with the fibers and polymer resin comprises a substantially smooth surface such that the fiber-reinforced composite door skin comprises at least one smooth surface.
82 . The method of claim 69 , wherein at least one of the die surfaces in contact with the fibers and polymer resin comprises a grain pattern such that the fiber-reinforced composite door skin comprises at least one surface having a grain pattern.
83 . The method of claim 69 , wherein the first die comprises a female die having a surface comprising at least one depression and the second die comprises a male die comprising at least one protrusion, such that when the mold is closed, the depression and the protrusion are aligned with each other.
84 . The method of claim 69 , wherein the dies are separated by a predetermined distance when the mold is closed.
85 . The method of claim 84 , wherein the predetermined distance ranges from 0.05 inches to 1.0 inch.
86 . A system for manufacturing a building structure comprising an introducing apparatus and a mold shaped to form a building structure.
87 . The system of claim 86 , wherein the introducing apparatus comprises a mixer for mixing at least two separate components required to form a polymer resin.
88 . The system of claim 86 , further comprising at least two conduits for introducing the two separate resin components into the mixer.
89 . The system of claim 86 , further comprising a chopper for chopping a plurality of fibers to a predetermined length.
90 . The system of claim 86 , further comprising a dispenser for dispensing at least one of the fibers or the polymer resin onto a surface of the mold.
91 . The system of claim 86 , wherein the fiber comprises a plurality of chopped fibers arranged in a non-structured, substantially random orientation.
92 . The system of claim 90 , further comprising a robotic controller for positioning the dispenser at different positions relative to the mold.
93 . The system of claim 86 , further comprising a means for controlling the temperature of at least a portion of the mold.
94 . The system of claim 86 , wherein the polymer resin comprises a thermosetting polymer.
95 . The system of claim 94 , wherein the thermosetting polymer comprises polyurethane.
96 . The system of claim 86 , wherein the fiber comprises fiberglass.
97 . The system of claim 96 , wherein the fiberglass ranges in length from about 5 mm to about 100 mm.
98 . The system of claim 86 , wherein the building structure comprises a substantially planar structure.
99 . The system structure of claim 98 , wherein the building structure comprises a door skin.
100 . The system of claim 99 , wherein the mold comprises two dies shaped to press a door skin.
101 . The system of claim 100 , wherein the first die comprises a female die having a surface comprising at least one depression and the second die comprises a male die comprising at least one protrusion, such that when the mold is closed, the depression and the protrusion are aligned with each other.
102 . The system of claim 100 , wherein at least a portion of at least one of the two dies is polished to a smooth finish.
103 . The system of claim 100 , wherein at least a portion of at least one of the two dies comprises a pattern etched in the surface.
104 . The system of claim 100 , wherein the dies are separated by a predetermined distance when the mold is closed.
105 . The system of claim 104 , wherein the predetermined distance ranges from 0.05 inches to 1.0 inch.
106 . The system of claim 86 , wherein the building structure comprises a panel.
107 . The system of claim 86 , wherein the building structure comprises cladding.
108 . The system of claim 86 , wherein the building structure comprises a door frame or a portion of a door frame.
109 . The system of claim 86 , wherein the building structure comprises a window frame or a portion of a window.
110 . The system of claim 86 , wherein the building structure comprises siding.
111 . The system of claim 86 , wherein the building structure comprises a shutter.
112 . The system of claim 86 , wherein the building structure comprises a shingle.