Claims:We claim:

1. A process for making frames with composite materials, said method comprises the steps of:

(a) obtaining a Fibre Reinforced Polymer (FRP) mould:

(b) simultaneously preparing Cellular Light-weight Concrete (CLC) mixture:

(c) filling said CLC mixture obtained at step (b) above into the cavity of FRP mould obtained at step (a) above, and releasing said filled FRP mould for curing; and

(d) steam curing of FRP frame mould filled with FRP and CLC mixture;

wherein said steam cured FRP frame mould is cut into targeted rail sizes for making frames according to the requirements.

2. Process as claimed in claim 1, wherein said Fibre Reinforced Polymer (FRP) mould is obtained by the steps of:

(i) preparing FRP by using unsaturated polyester resin blended with a pigment gel;

(ii) applying said FRP over said frame mould and curing thereof;

(iii) applying a reinforcing chopped polyester strand mat over said FRP layer coated frame mould; and

(iv) applying a layer of said unsaturated polyester resin blended with the same pigment gel over said chopped polyester strand mat layer of frame mould until complete wetting thereof.

3. Process as claimed in claim 1, wherein said Cellular Light-weight Concrete (CLC) mixture is obtained by the steps of:

(I) dry mixing by volume about 50% of Ordinary Portland Cement (OPC) with 25% fly-ash to obtain a mixture thereof;

(II) adding 20% of protein-based foaming agent and about 5% of rubber-based additives to aforesaid OPC to fly-ash mixture; and

(III) mixing the mixtures obtained at process steps (I) and (II) thoroughly.

4. FRP frame made by the process as claimed in claim 1 to 3, wherein said FRP mould is cut into targeted rail sizes for making frames according to the requirements.

5. FRP frame as claimed in claim 4, wherein said frame is made of a plurality of rails cut from said FRP frame mould filled with FRP and CLC mixture and fixed together using a plurality of L-joints and T-joints made in a predefined configuration by means of fasteners.

6. FRP frame as claimed in claim 5, wherein said frame is made for a door or window frame.

7. FRP frame as claimed in claim 6, wherein said frame comprises:

(A) a pair of side rails;

(B) a top rail fixed at the top end of said side rails; and

(C) a middle rail fixed away from said top rail;

wherein a ventilation space is formed between said top rail and middle rail, preferably for fixing a ventilator frame therebetween.
8. FRP frame as claimed in claim 7, wherein said top rail, middle rail and side rails are secured together by means of screws.

9. FRP frame as claimed in anyone of claims 4 to 8, wherein a wooden strip is removably fixed between said side rails for keeping said FRP frame in true rectangular shape until installation thereof at the site.

10. FRP frame as claimed in claim 9, wherein a plurality of plastic hole grips or anchors are provided on said FRP frame for installation thereof at site.
Digitally Signed.

Dated: this 28th day of December 2018. (SANJAY KESHARWANI)
APPLICANTS’ PATENT AGENT
For: MAHINDRA LIFESPACE DEVELOPERS LTD.
, Description:FIELD OF THE INVENTION

The present invention relates to a process of making frames used in the construction industry. In particular, the present invention relates to the frames made of composite elements. More particularly, the present invention relates to frames made of elements of composite materials, such as Cellular Light-weight Concrete (CLC) and Fiber Reinforced Polymer (FRP) moulds.

BACKGROUND OF THE INVENTION

Conventionally, in civil constructions, e.g. residential or commercial/office buildings, the overall cost of the projects depends on the individual costs of each and every ingredient and components. One of the most important components in any residential or commercial/office building is the frames used for fixing doors and/or windows in the walls or openings at predetermined places.

These door and window frames are normally made of wood, concrete, fiberglass, aluminum, or vinyl. In recent times, unplasticized polyvinyl chloride (uPVC) is also being used for this purpose. These door and window frames are costly and also require substantial costs of maintenance in terms of frequent painting and polishing.

PRIOR ART

For a long time, natural wood was being used for door and window frames, because there was less population and forests were present in abundance. Door and window frames made of wood are prone to termite attacks. In the fast dwindling forest covers in recent decades, wood has gradually become a scarce natural resource.
However, modern day industrialization hastened the progress of the construction industry, be it for industries or for residential or commercial buildings. This also led to a very fast depletion of natural resources, including natural wood.

As a result, mild steel door and window frames have found acceptance in the construction industry due to their ruggedness and ease of welding and shaping. But these frames tend to be much heavier and costlier as compared to the wooden ones. Furthermore, above-described mild steel door and window frames are prone to deteriorating in inclement weather conditions, such as rains, exposure to sunlight and in humid climates.

Therefore, the maintenance costs, e.g. painting and polishing of wooden or metallic frames are also substantially higher, thereby increasing the initial cost of the construction as well as the cost of maintaining the buildings made using the same.

In particular, the dead weight of metallic door and window frames is much higher than those made of wood. This also leads to increasing the dead load on the building structure, which in turn increases the overall cost of construction.

Even, using non-plasticized polyvinyl chloride (uPVC) did not help the construction industry much, because of the unsatisfactory bending and compressive strength of uPVC.

Therefore, it was felt necessary to improve the performance by reducing the overall cost of construction and also to make the production process more environment friendly. The material for such frames should not cause any harmful effect on the environment as well.
Therefore, developing alternative material/s for making cost-efficient, easy to maintain door/window frames was given a thought for better performance and preventing deterioration under unfavorable weather conditions.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

The object of the present invention is to provide a composite material frame element to replace the conventionally used materials.

Another object of the present invention is to provide a composite material frame element, which is light-weight, thus reduces the dead load on structures.

Yet another object of the present invention is to provide a composite material frame element, which is more economical to produce.

Still another object of the present invention is to provide a composite material frame element, which uses industrial by-products that are difficult to be disposed of.

A further object of the present invention is to provide a composite material frame element, which improves worker’s productivity and is thus cost-effective.

A still further object of the present invention is to provide a composite material frame element, which has a favorable ratio of bending strength to compressive strength.

Another object of the present invention is to provide a composite material frame element, which is maintenance-free.
A yet further object of the present invention is to provide a composite material frame element, which has excellent dimensional stability.

Another object of the present invention is to provide a composite material frame element, which is water proof and termite proof.

A yet another object of the present invention is to provide a composite material frame element, which shows improved fire rating.

Still another object of the present invention is to provide a composite material frame element, which is biodegradable.

These and other objects and advantages of the present invention will become more apparent from the following description when read with the accompanying figures of drawing, which are, however, not intended to limit the scope of the present invention in any way.

DESCRIPTION OF THE INVENTION

In order to achieve the above-mentioned objects of the present invention and to overcome the disadvantages associated with the existing frame elements, such as door and window frames used in construction industry, a composite material frame element has been developed in accordance with the present invention.

This product consists of a frame made of composite material of Cellular Light-weight Concrete (CLC) and Fibre Reinforced Polymer (FRP). This composite material has proven to be an excellent replacement of the materials such as wood, non-plasticized poly(vinyl chloride) (uPVC), concrete or metal conventionally used, e.g. for making door or window frames for construction industry.
The method of using Cellular Light-weight Concrete (CLC) in accordance with the invention for obtaining the novel composite material involves dry mixing, for example, 50% by volume of Ordinary Portland Cement (OPC) with 25% by volume of fly-ash. Subsequently, 20% of protein-based foaming agent and adding about 5% of rubber based additives to said OPC and fly-ash mixture.

In accordance with the invention, Fibre Reinforced Polymer (FRP) material used for obtaining the novel composite material is prepared by using unsaturated polyester resin, which is blended with a pigment laid over the FRP frame mould and then to allow curing thereof.

Subsequently, polyester chopped strand mat (E-class 450 GSM) is laid over the layer of unsaturated blended polyester resin obtained above. This polyester chopped strand mat acts as reinforcement in FRP layer. Being a product readily available in market, the curing of polyester chopped strand mat is not required.

Again, a layer of unsaturated polyester resin blended with the same pigment is laid over this polyester chopped strand mat (acting as adhesive for receiving the CLC filler) applied heavily until it completely wets the polyester chopped strand mat. Now, the polyester chopped strand mat is allowed to cure. Subsequently, CLC is filled in FRP frame cavities and the frame moulding is removed after CLC has dried after about 2-3 days.

Being concrete, it is subjected to curing for about 28 days for attaining the full strength thereof. But it was experimented and established by trials that by using steam curing, the aforesaid curing period was reduced to almost half, i.e. just in 14 days, thereby making the frame production process substantially faster.

The single piece composite mould is then cut in desired size shape and frames are prepared using adhesives and screws at the factory.
Finally, these frames are transported to the construction site, where they are fixed in the walls and openings as per the specifications, construction drawings and layouts. The gaps between the frames and the masonry wall/openings are filled up with mortar or putty in conventional manner.

This invention offers a unique product, which makes use of Cellular Light-weight Concrete (CLC) along with Fibre Reinforced Polymer (FRP) for manufacturing of frames, especially door/window frames of modern buildings.

This product is totally different from any such product available in the Indian market presently using wooden, metal, only concrete, only Fibre Reinforced Polymer (FRP) and non-plasticized poly(vinyl chloride) (uPVC) materials for manufacturing of frames.

SUMMARY OF THE INVENTION

In accordance with an embodiment of the present invention, there is provided a process for making frames with composite materials, the method comprises the steps of:

(a) obtaining a Fibre Reinforced Polymer (FRP) mould:

(b) simultaneously preparing Cellular Light-weight Concrete (CLC) mixture:

(c) filling the CLC mixture obtained at step (b) above into the cavity of FRP mould obtained at step (a) above, and releasing the filled FRP mould for curing; and

(d) steam curing of FRP frame mould filled with FRP and CLC mixture;

wherein the steam cured FRP frame mould is cut into targeted rail sizes for making frames according to the requirements.

Typically, the Fibre Reinforced Polymer (FRP) mould is obtained by the steps of:

(i) preparing FRP by using unsaturated polyester resin blended with a pigment gel;

(ii) applying the FRP over the frame mould and curing thereof;

(iii) applying a reinforcing chopped polyester strand mat over the FRP layer coated frame mould; and

(iv) applying a layer of the unsaturated polyester resin blended with the same pigment gel over the chopped polyester strand mat layer of frame mould until complete wetting thereof.

Typically, the Cellular Light-weight Concrete (CLC) mixture is obtained by the steps of:

(I) dry mixing by volume about 50% of Ordinary Portland Cement (OPC) with 25% fly-ash to obtain a mixture thereof;

(II) adding 20% of protein-based foaming agent and about 5% of rubber-based additives to the OPC to fly-ash mixture; and

(III) mixing the mixtures obtained at process steps (I) and (II) thoroughly.

In accordance with the present invention, there is also provided a FRP frame made by the process above, wherein the FRP mould is cut into targeted rail sizes for making frames according to the requirements.

Typically, the frame is made of a plurality of rails cut from the FRP frame mould filled with FRP and CLC mixture and fixed together using a plurality of L-joints and T-joints made in a predefined configuration by means of fasteners.

Typically, the frame is made for a door or window frame.

Typically, the frame comprises:

(A) a pair of side rails;

(B) a top rail fixed at the top end of the side rails; and

(C) a middle rail fixed away from the top rail;

wherein a ventilation space is formed between the top rail and middle rail, preferably for fixing a ventilator frame therebetween.

Typically, the top rail, middle rail and side rails are secured together by means of screws.

Typically, a wooden strip is removably fixed between the side rails for keeping the FRP frame in true rectangular shape until installation thereof at the site.

Typically, a plurality of plastic hole grips or anchors are provided on the FRP frame for installation thereof at site.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will now be explained in more detail with reference to the non-limiting accompanying drawings of the frames made of a composite material consisting of Cellular Light-weight Concrete (CLC) and Fiber Reinforced Polymer (FRP), in which:

Figure 1 shows a flow chart of the process for manufacturing frames made of a composite material consisting of Cellular Light-weight Concrete (CLC) and Fiber Reinforced Polymer (FRP) in accordance with the present invention;

Figure 2a shows a front view of an exemplary door frame made by the process illustrated in Figure 1;

Figure 2b shows a sectional side view of the door frame shown in Figure 2a;

Figure 2c shows an enlarged view of one of the two “L” type joints of the door frame shown in Figure 2a;

Figure 2d shows an enlarged view of one of the two “T” type joints of the door frame shown in Figure 2a;

Figure 2e shows another enlarged sectional side view of the top corner of the door frame shown in Figure 2b;

Figure 3 shows a perspective view of the door frame shown in Figure 2a;

Figure 4a shows an opening in the wall or building for fixing the door frame;

Figure 4b shows the door frame shown in Fig. 4b while checking right angles;

Figure 4c shows a side view of the door frame shown in Figure 4b while checking its perpendicularity with respect to the ground;

Figure 4d shows an end of the door frame shown in Figure 4a, with one of the holes provided for installing the door frame in the wall or opening in the construction by means of hole grips or anchors;

Figure 5 shows a perspective view of a door frame in accordance with the present invention fixed in the building;

Figure 6 shows a door frame rail’s cross-section, clearly indicating the CLC and FRP mixture filled inside the door frame prior to its curing; and

Figure 7 shows a sample of CLC + FRP cladded door frame fixed with a hinge by means of screws.

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The frame made in accordance with the present invention will now be described in detail with reference to the accompanying drawings, without limiting the scope and ambit of the disclosure in any way.

Figure 1 shows a flow chart including the process for manufacturing a frame in accordance with the present invention, for example a door or window frame made of elements with composite materials of Cellular Light-weight Concrete (CLC) and Fiber Reinforced Polymer (FRP). At step 10, CLC mixture is prepared by dry mixing 50% by volume of Ordinary Portland Cement (OPC) with 25% by volume of fly-ash. Subsequently at step 12, 20% of protein based foaming agent and about 5% of rubber based additives are added to above mixture of OPC and fly-ash and mixed thoroughly. Along with forming the CLC mixture at steps 10 and 12, Fiber Reinforced Polymer (FRP) is simultaneously prepared by using unsaturated polyester resin blended with pigment gel. In step 20, this is applied over the frame mould to form a layer thereof and allowed for curing. At step 22, the polyester chopped strand mat (E-class 450 GSM) is laid over the aforesaid layer to act as reinforcement in the FRP layer. Then in step 24, a layer of unsaturated polyester resin blended with the same pigment gel acting as adhesive for CLC filler being received, is again applied over the above coated mat until wetting thereof completely. Now at step 26, the CLC mixture obtained at step 12 is filled inside the FRP cavity. Now at step 28, the Frame mould is released after 2-3 days and left for curing. To speed-up the curing process, the steam curing process was used, which halved the curing time from normal 28 days to just 14 days. After this 14 day curing, the frame element filled with FRP and CLC mixture is now ready to be cut into desired lengths at step 30, for making top rails, side rails and bottom rails in sizes according to the building specification and layout to obtain the targeted door and window frame size. Accordingly, at step 32, the top, side and bottom rails are assembled into a door frame, by using screws to obtain door or window frames of targeted dimensions to be fixed in the building structures as per the designed layouts. Finally, these ready-to-use door and window frames are transported to construction site for fitting in respective positions in the conventional manner.

Figure 2a shows a front view of the door frame made by the process described in Figure 1 discussed above. The door frame 32 has two different joints, i.e. joint 40 is an “L” joint and joint 50 is a “T” joint. Enlarged view of these “L’ and “T” joints are shown in Figures 2c and Figure 2c and discussed in detail below.

Figure 2b shows a sectional side view of the door frame 32 shown in Fig. 2a, indicating the cross-sections of “L” and “T” joints 40 and 50 in Figures 2c, 2d.

Figure 2c shows an enlarged view of one of the two “L” type joints 40 of the door frame 32 made shown in Figure 2a.

Figure 2d shows an enlarged view of one of the two “T” type joints 50 of the door frame 32 shown in Figure 2a.

Figure 2e shows an enlarged sectional view of the top corner of the door frame, i.e. of the “L” joint at 40 as shown in Figures 2a, 2b. It indicates the cross-section of the door frame elements filled and cured with CRC and FRP mixture 26 for obtaining the desired door and/or window frame 32 made in accordance with the present invention.

Figure 3 shows a perspective view of the door frame 32 shown in Figure 2a. It consists of two longer side rails 38, which are fixed at top corners by metal brackets 44 using screws to the shorter top rail 42. The shorter middle rail 36 is also fixed between the two longer side rails 38 by means of screws 34 creating a space for ventilation or for fixing a ventilator frame. A wooden strip 46 keeps the door frame in true rectangular shape until installation thereof at the correct position in the wall opening 48. This wooden strip 46 should only be removed after installing and securing the door frame in the wall opening 48 therefor and before fitting the door in the door frame 32.

Figure 4a shows an opening 48 in the wall or building for fixing the door frame.

Figure 4b shows the door frame 32 shown in Figures 2a, 3, which is fixed with a wooden strip 46 to keep its true rectangular shape by keeping the top and side rails thereof exactly at right angles with respect to each other. There are eight locations marked by reference numerals 1 to 8 for installing anchors and plastic hole grips 52 shown in Figure 4d as described below.

Figure 4c shows a side view of the door frame shown in Figure 4b while checking its perpendicularity with respect to the ground before fixing the wooden strip 46.

Figure 4d shows an end of the door frame shown 32 with one of the plastic hole grips or anchors 52 therein provided for installing the door frame in the wall or opening in the construction.

Figure 5 shows a perspective view of a door frame made in accordance with the present invention fixed in a modern building.

Figure 6 shows a cross-section of the door frame rail, clearly indicating the mixture of CRC and FRP filled inside the door frame prior to its curing.

Figure 7 shows a sample of CLC + FRP cladded door frame fixed with a hinge by means of screws.

TECHNICAL ADVANTAGES & ECONOMIC SIGNIFICANCE

The frames made of composite elements for modern building configured in accordance with the invention has the following advantages:
• Light weight than wooden, concrete or any other door or window frames presently in use.

• Offer about 70% cost-reduction w. r. t. door or window frames presently in use.

• Provide excellent compressive strength w. r. t. frames presently in use and having a bending strength 15-20% of its compressive strength.

• Density is 800 kilograms per square meter which reduces the dead load on structures.

• Easy to assemble, handle, transport, stock and fix by screwing.

• Excellent dimensional stability.

• Utilizes 25% of an industrial waste by-product i.e. fly-ash.

• Termite and water proof.

• Quality product, every time.

• 100% replacement of wood in frames.

• Excellent dimensional stability i.e. no warping and shrinkage.

• Approximately 2 hours of Fire rating.

• Customizable, 100% biodegradable, eco-friendly & sustainable product.

• Quick to install, thus reduces cycle time.

It is to be understood that the present invention is not limited in its application to the details of the construction and to the arrangements of the components as mentioned in the above description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the terminologies used herein are for the purpose of description and should not be regarded as limiting.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept.

Therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

The description provided herein is purely by way of example and illustration. The various features and advantageous details are explained with reference to this non-limiting embodiment in the above description in accordance with the present invention.

The descriptions of well-known components and manufacturing and processing techniques are consciously omitted in this specification, so as not to unnecessarily obscure the specification. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

Therefore, while the embodiments herein have been described in terms of preferred embodiments, the skilled person will recognize that the embodiments herein can be practiced with modification within the spirit and scope of embodiments described herein.

The skilled person can easily make innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies, assemblies and in terms of the size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification, the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.