Polyurethanes Open the Door to Improved Strength and Aesthetics
June 24, 2005
LEVERKUSEN -- This summer, JELD-WEN will launch a new exterior door line - JELD-WEN Premium Fiberglass Doors with PUR-Fiber technology. The skins of these doors are molded from a customized formulation of polyurethane materials from Bayer MaterialScience LLC, Pittsburgh, USA.
Bayer MaterialScience worked closely with JELD-WEN, the world?s leading manufacturer of windows and doors, to develop a formulation from Baytec® SPR spray polyurethane and Baydur® STR polyurethane specifically for this application. Use of these polyurethane materials gives the doors increased dimensional stability, better impact resistance and strength, along with the excellent aesthetics consumers demand.
"We evaluated several potential materials suppliers, but in our opinion, Bayer MaterialScience had the right combination of materials, technology and technical expertise we were looking for," said Craig Turner, coordinating general manager for JELD-WEN, which is based in Klamath Falls, Oregon. "Based on the results of the molding trials, we selected Bayer MaterialScience as our strategic supplier."
The skins of the doors are formed using long fiber technology, in which long glass fibers are injected along with polyurethane resin in a one-step process. To complete the door manufacturing process, JELD-WEN laminates the composite door skins to a polystyrene core and wood edge frame.
Long fiber technology improves economics of molding
In long fiber technology, a fiberglass chopper is attached to the polyurethane dispensing mixhead, which is attached to a robot. The robot is programmed to move over the open mold cavity while simultaneously dispensing both the long glass fibers and the polyurethane resin in an open-pour method. At the end of the pour, the mold is closed to form the part.
"Long fiber technology is helping to automate the polyurethane process for producing composite parts, making them more economical to produce via this method," explained Harry George, business manager, Specialty RIM Group for Bayer MaterialScience LLC.
The unique benefits of long fiber technology include:
Ability to utilize lower-cost fiberglass rovings rather than mats, which also reduces troublesome worker handling of the mats;
Ability to vary the amount of fiberglass reinforcement in the part to focus high strength where it is most needed;
Ability to use either a foamed or solid polyurethane formulation;
and,
Ability to produce parts with polyurethane in-mold coating, thus eliminating secondary painting operations.
When they hit the market this July, the JELD-WEN Premium Fiberglass Doors with PUR fiber technology will be available in 32 different designs and three graining patterns (oak, mahogany and alder). "Offering products that combine exceptional value with reliability is the cornerstone of our business," said Turner. "With its innovative materials and molding process, this new door line is an excellent example of our commitment to this ideal."
