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Composite Door Application

The unique properties of Acell’s Mineral Filled Phenolic foam enables Thermo-set and Themo-plastic faced doors to be manufactured to a specification which can be amended to meet specific specification requirements, whether it be for security, weather performance, fire resistance, sound and thermal insulation or a combination.

In the case of fire resistance for example, both Acell’s Polyester (GRP) and Thermo-plastic faced doors can be hung into an appropriate frame and with the inclusion of intumesant materials incorporated into the frame and around the hardware will achieve a 30 minute fire resistance rating.

In comparison to other foam filled composite doors, when subjected to fire, the Acell foam core does not emit poisonous gases (cyanide compounds etc.) or dense black obscuring smoke, which can pose more of a threat to life during a house fire than the fire itself. This potential lifesaving feature of Acell foam is applicable to all Acell specification doors, not just those doors manufactured specifically to achieve a fire resistant rating.

When considering the Acell Composite Door Specification and Performance with other methods used to manufacture foam filled composite doors, the unique features of Acell foam combined with Acell process and in-mould finishing technology, provides our composite door Licensees with a finished door which will provide all the benefits listed above and a long service life requiring minimal maintenance.

Comparison Of Various Types Of Foam Filled Composite Doors

Comparison

Sheet Moulded Compound
(Smc)

Resin Transfer Method
(Rtm)

Grp Hand
Lay-up
Method

Other
Themo-plastic
Faced Doors
Acell Automated Grp Acell
Thermo-plastic
Faced
Doors
Aesthetics Synthetic Graining Moulded from original materials
but design is limited by resin flow
– timber etc
Moulded from any original material, design is not limited by resin flow properties Moulded from any original material, design is not limited by resin flow properties Moulded from any original material, design is not limited by resin flow properties Moulded from any original material, design is not limited by resin flow properties
Finish Requires surface finish to be applied post production Solid colours can be provided in mould but staining is applied post production Solid colours can be provided in mould but staining is applied post production Solid colours can be provided in mould but staining is applied post production Solid colours and finished woodgrain can be made directly from the mould without the need to finish post production Solid colours can be provided in mould but staining is applied post production

Life-time Maintenance

Maintenance is required Low maintenance of solid colours but maintenance is required for stained finishes Low maintenance of solid colours but maintenance is required for stained finishes Low maintenance of solid colours but maintenance is required for stained finishes Cleaning only, maintenance free faces Low maintenance of solid colours but maintenance is required for stained finishes
Core Material Injected pu foams, solid styrene/pu/expanded polystyrene, laminated timber Injected pu foams, solid styrene/pu/expanded polystyrene, laminated timber Injected pu foams, solid styrene/pu/expanded polystyrene, laminated timber Injected pu foams, solid styrene/pu/expanded polystyrene, laminated timber Acell phenolic structural foam Acell phenolic structural foam
Bond Glue line or chemical adhesion of expanding foam Glue line or chemical adhesion of expanding foam Glue line or chemical adhesion of expanding foam Glue line or chemical adhesion of expanding foam Chemical and mechanical bond to the foam core Chemical and mechanical bond to the foam core
Thermal Stabilityclimate Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Heating to 80oc – classification class 3 Heating to 80oc – classification class 3
Chamber Testingdd171 Andpren1121 Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Heating to 40oc – results unknown but allowance of 10mm Highest available indicating a bow of less than 2mm Highest available indicating a bow of less than 2mm
Fire Rating Available Special construction Special construction Special construction Special construction Standard door Standard door
Lamination Stability Reliant on glue line and integrity of core material Reliant on glue line and integrity of core material Reliant on glue line and integrity of core material Reliant on glue line and integrity of core material Facing becomes an integral part of the entire panel and cannot suffer delamination
******
Monolothic structure
Reliant on glue line to skin but chemical and mechanical bond to foam core
Face Repairability Minimal repairs can be made Surface scatches can be repaired Fully repairable Fully repairable Fully repairable Fully repairable
Production Methods Facings and doors automated industrial Facings and doors automated industrial Workshop production Facings and doors automated industrial Automated industrial Facings and doors automated industrial
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