CA2485531A1 - A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof - Google Patents
A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof Download PDFInfo
- Publication number
- CA2485531A1 CA2485531A1 CA002485531A CA2485531A CA2485531A1 CA 2485531 A1 CA2485531 A1 CA 2485531A1 CA 002485531 A CA002485531 A CA 002485531A CA 2485531 A CA2485531 A CA 2485531A CA 2485531 A1 CA2485531 A1 CA 2485531A1
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- CA
- Canada
- Prior art keywords
- fibers
- layer
- part according
- resin
- wall
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/525—Component parts, details or accessories; Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres
- B29C70/202—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel fibres arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC]
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
A method for forming a pultruded part includes collating reinforcing fibers by providing a first layer of reinforcing rovings extending in the longitudinal pultrusion direction, applying onto the first layer an intermediate layer of reinforcing fibers at least some of which include at least portions thereof which extend in the transverse direction and covering the intermediate layer with a second layer of rovings extending in the longitudinal direction. To the collated fibers is applied a resin so as to permeate through the layers and the materials are passed through a die to set the resin. The first and second layers are arranged to form first and second opposed surfaces of the part with the intermediate layer therebetween.
The resin is a two part urethane resin which has sufficient strength to prevent the fibers from the first and second layers at the first and second surfaces respectively from breaking through the surface on bending of the wall thus allowing the use of the rovings at the surfaces with the transverse fibers therebetween so that the transverse fibers can be formed from loose or chopped fiber material from rovings rather than more expensive mat.
The resin is a two part urethane resin which has sufficient strength to prevent the fibers from the first and second layers at the first and second surfaces respectively from breaking through the surface on bending of the wall thus allowing the use of the rovings at the surfaces with the transverse fibers therebetween so that the transverse fibers can be formed from loose or chopped fiber material from rovings rather than more expensive mat.
Claims (42)
1. A pultruded part comprising:
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a pultrusion direction and having a transverse width transverse to the longitudinal pultrusion direction;
fiber layers within the wall;
a non-linear resin material permeated through the fiber layers and filling the thickness between the surfaces so as to define the surfaces;
the fiber layers including at least one first layer of fibers having fibers extending only in the longitudinal pultrusion direction;
the fiber layers including one or more second layers, the or each second layer consisting solely of a layer of fibers such that the resin is permeated through the layer of fibers between the fibers, the or each second layer having fibers with at least portions thereof extending transverse to the longitudinal direction;
the or each second layer of fibers having a total quantity of fibers in the layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a pultrusion direction and having a transverse width transverse to the longitudinal pultrusion direction;
fiber layers within the wall;
a non-linear resin material permeated through the fiber layers and filling the thickness between the surfaces so as to define the surfaces;
the fiber layers including at least one first layer of fibers having fibers extending only in the longitudinal pultrusion direction;
the fiber layers including one or more second layers, the or each second layer consisting solely of a layer of fibers such that the resin is permeated through the layer of fibers between the fibers, the or each second layer having fibers with at least portions thereof extending transverse to the longitudinal direction;
the or each second layer of fibers having a total quantity of fibers in the layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
2. The pultruded part according to Claim 1 wherein the resin is a cross-linked resin.
3. The pultruded part according to Claim 1 wherein the resin is a thermoset cross-linked polyurethane.
4. The pultruded part according to Claim 1 wherein the resin is a multi-functional resin.
5. The pultruded part according to Claim 1, 2, 3 or 4 wherein at least one part of the wall is reinforced through its thickness solely by fibers extending only in the longitudinal pultrusion direction.
6. The pultruded part according to any one of Claims 1 to 5 wherein the or each second layer of fibers each has a total quantity of fibers which is in the range 0.25 ounces per square foot to 0.328 ounces per square foot.
7. The pultruded part according to any one of Claims 1 to 6 wherein the or each second layer of fibers comprises an entangled layer of staple fibers.
8. The pultruded part according to any one of Claims 1 to 7 wherein the or each second layer of fibers is a scrim or mesh having openings for penetration of the resin between the fibers.
9. The pultruded part according to any one of Claims 1 to 8 wherein the wall includes a leg portion thereof connected to a main body portion of the wall only at one end of the leg so as to define a second free end of the leg and wherein reinforcing fibers in the leg consist solely of fibers extending only in the longitudinal pultrusion direction.
The pultruded part according to Claim 9 wherein the leg portion has a wall that is thicker than that of the main body portion.
11. The pultruded part according to any one of Claims 1 to 10 wherein the or each second layer includes transverse fibers which are formed of metal strands which provide both transverse strength and the characteristic of electrical conductivity and/or ferromagnetism.
12. A pultruded part comprising:
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
one layer formed wholly of longitudinal fibers where the fibers of said one layer extend only in the longitudinal pultrusion direction and are located at the first surface;
another layer formed wholly of longitudinal fibers where the fibers of said another layer extend only in the longitudinal pultrusion direction and are located at the second surface;
an intermediate layer formed wholly of fibers such that the resin is permeated through the layer of fibers between the fibers;
some or all of the fibers of the intermediate layer having at least portions thereof which are transverse to the longitudinal direction wherein the intermediate layer is located between said one layer and said another layer;
and wherein the intermediate layer of fibers has a total quantity of fibers in the intermediate layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
one layer formed wholly of longitudinal fibers where the fibers of said one layer extend only in the longitudinal pultrusion direction and are located at the first surface;
another layer formed wholly of longitudinal fibers where the fibers of said another layer extend only in the longitudinal pultrusion direction and are located at the second surface;
an intermediate layer formed wholly of fibers such that the resin is permeated through the layer of fibers between the fibers;
some or all of the fibers of the intermediate layer having at least portions thereof which are transverse to the longitudinal direction wherein the intermediate layer is located between said one layer and said another layer;
and wherein the intermediate layer of fibers has a total quantity of fibers in the intermediate layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
13. The pultruded part according to Claim 12 wherein the resin is a cross-linked resin.
14. The pultruded part according to Claim 12 wherein the resin is a thermoset cross-linked polyurethane n.
15. The pultruded part according to Claim 12 wherein the resin is a multi-functional resin.
16. The pultruded part according to any one of Claims 12 to 15 wherein the intermediate layer of fibers has a total quantity of fibers therein which is in the range 0.25 ounces per square foot to 0.328 ounces per square foot.
17. The pultruded part according to any one of Claims 12 to 16 wherein the intermediate layer of fibers comprises an entangled layer of staple fibers.
18. The pultruded part according any one of Claims 12 to 17 wherein the intermediate layer is a scrim or mesh having openings for penetration of the resin between the fibers.
19. The pultruded part according to any one of Claims 12 to 18 wherein the wall includes a leg portion thereof connected to a main body portion of the wall only at one end of the leg so as to define a second free end of the leg and wherein reinforcing fibers in at least part of the leg consist solely of fibers extending only in the longitudinal pultrusion direction.
20. The pultruded part according to Claim 19 wherein the leg portion has a wall that is thicker than that of the main body portion.
32~
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21. The pultruded part according to any one of Claims 12 to 20 wherein the fibers of the intermediate layer are formed of metal strands which provide both transverse strength and the characteristic of electrical conductivity and/or ferromagnetism for the part.
22. A pultruded part comprising:
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a longitudinal pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
the wall defining a peripheral wall fully surrounding a hollow interior such that the first surface faces outwardly and the second surface faces inwardly;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
a first layer formed wholly of longitudinal fibers where the fibers of the first layer extend only in the longitudinal pultrusion direction; and a second layer defined by a pre-formed two dimensional mat having fibers of the mat with at least portions thereof extending transverse to the longitudinal direction;
the first and second layers being in contact at a location between the first and second surfaces;
the first layer being located at the first surface such that some of the longitudinal fibers thereof are located at the first surface;
and the second layer being located at the second surface such that some of the transverse portions of the fibers are located at the first surface and such that the first layer is spaced from the second surface over the whole of the second surface by the second layer;
the second layer of fibers having a total quantity of fibers in the layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a longitudinal pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
the wall defining a peripheral wall fully surrounding a hollow interior such that the first surface faces outwardly and the second surface faces inwardly;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
a first layer formed wholly of longitudinal fibers where the fibers of the first layer extend only in the longitudinal pultrusion direction; and a second layer defined by a pre-formed two dimensional mat having fibers of the mat with at least portions thereof extending transverse to the longitudinal direction;
the first and second layers being in contact at a location between the first and second surfaces;
the first layer being located at the first surface such that some of the longitudinal fibers thereof are located at the first surface;
and the second layer being located at the second surface such that some of the transverse portions of the fibers are located at the first surface and such that the first layer is spaced from the second surface over the whole of the second surface by the second layer;
the second layer of fibers having a total quantity of fibers in the layer which is in the range 0.25 ounces per square foot to 0.5 ounces per square foot.
23. ~The pultruded part according to Claim 22 wherein the resin is a cross-linked resin.
24. ~The pultruded part according to Claim 22 wherein the resin is a thermoset cross-linked polyurethane.
25. ~The pultruded part according to Claim 22 wherein the resin is a multi-functional resin.
26. ~The pultruded part according to any one of Claims 22 to 25 wherein the second layer of fibers has a total quantity of fibers therein which is in the range 0.25 ounces per square foot to 0.328 ounces per square foot.
27. ~The pultruded part according to any one of Claims 22 to 26 wherein the second layer of fibers comprises an entangled layer of staple fibers.
28. ~The pultruded part according to any one of Claims 22 to 27 wherein the second layer is a scrim or mesh having openings for penetration of the resin between the fibers.
29. The pultruded part according to any one of Claims 22 to 28 wherein the wall includes a leg portion thereof connected to a main body portion of the wall only at one end of the leg so as to define a second free end of the leg and wherein reinforcing fibers in at least part of the leg consist solely of fibers extending only in the longitudinal pultrusion direction.
30. The pultruded part according to Claim 29 wherein the leg portion has a wall that is thicker than that of the main body portion.
31. The pultruded part according to any one of Claims 22 to 30 wherein at least one part of the wall is reinforced through its thickness solely by fibers extending only in the longitudinal pultrusion direction.
32. The pultruded part according to any one of Claims 22 to 31 wherein the fibers of the second layer are formed of metal strands which provide both transverse strength and the characteristic of electrical conductivity and/or ferromagnetism for the part.
33. A pultruded part comprising:
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a longitudinal pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
the wall defining a peripheral wall fully surrounding a hollow interior such that the first surface faces outwardly and the second surface faces inwardly;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
a first layer formed wholly of longitudinal fibers where the fibers of the first layer extend only in the longitudinal pultrusion direction; and a second layer formed wholly of fibers such that the resin is permeated through the layer of fibers between the fibers;
the second layer being defined by a pre-formed two dimensional mat having fibers of the mat with at least portions thereof extending transverse to the longitudinal direction;
the first and second layers being in contact at a location between the first and second surfaces;
the first layer being located at the first surface such that some of the longitudinal fibers thereof are located at the first surface;
and the second layer being located at the second surface such that some transverse fiber portions are located at the first surface and such that the first layer is spaced from the second surface over the whole of the second surface by the second layer.
a wall having a first surface and a second surface spaced by a thickness of the part, the wall extending longitudinally in a longitudinal pultrusion direction and having a transverse direction transverse to the longitudinal pultrusion direction;
the wall defining a peripheral wall fully surrounding a hollow interior such that the first surface faces outwardly and the second surface faces inwardly;
reinforcing fibers within the wall;
a non-linear resin material permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
the reinforcing fibers consisting of:
a first layer formed wholly of longitudinal fibers where the fibers of the first layer extend only in the longitudinal pultrusion direction; and a second layer formed wholly of fibers such that the resin is permeated through the layer of fibers between the fibers;
the second layer being defined by a pre-formed two dimensional mat having fibers of the mat with at least portions thereof extending transverse to the longitudinal direction;
the first and second layers being in contact at a location between the first and second surfaces;
the first layer being located at the first surface such that some of the longitudinal fibers thereof are located at the first surface;
and the second layer being located at the second surface such that some transverse fiber portions are located at the first surface and such that the first layer is spaced from the second surface over the whole of the second surface by the second layer.
34. The pultruded part according to Claim 33 wherein the resin is a cross-linked resin.
35. The pultruded part according to Claim 33 wherein the resin is a thermoset cross-linked polyurethane.
36. The pultruded part according to Claim 33 wherein the resin is a multi-functional resin.
37. The pultruded part according to any one of Claims 33 to 36 wherein the second layer of fibers comprises an entangled layer of staple fibers.
38. The pultruded part according to any one of Claims 33 to 37 wherein the second layer is a scrim or mesh having openings for penetration of the resin between the fibers.
39. The pultruded part according to any one of Claims 33 to 38 wherein the wall includes a leg portion thereof connected to a main body portion of the wall only at one end of the leg so as to define a second free end of the leg and wherein reinforcing fibers in at least part of the leg consist solely of fibers extending only in the longitudinal pultrusion direction.
40. The pultruded part according to Claim 39 wherein the leg portion has a wall that is thicker than that of the main body portion.
41. The pultruded part according to any one of Claims 33 to 40 wherein at least one part of the wall is reinforced through its thickness solely by fibers extending only in the longitudinal pultrusion direction.
42. The pultruded part according to any one of Claims 33 to 41 wherein the fibers of the second layer are formed of metal strands which provide both transverse strength and the characteristic of electrical conductivity and/or ferromagnetism for the part.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2485531A CA2485531C (en) | 2002-06-12 | 2002-06-12 | A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002390468A CA2390468C (en) | 2001-06-14 | 2002-06-12 | A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof |
| CA2485531A CA2485531C (en) | 2002-06-12 | 2002-06-12 | A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002390468A Division CA2390468C (en) | 2001-06-14 | 2002-06-12 | A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2485531A1 true CA2485531A1 (en) | 2002-12-14 |
| CA2485531C CA2485531C (en) | 2010-02-23 |
Family
ID=34069882
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2485531A Expired - Fee Related CA2485531C (en) | 2002-06-12 | 2002-06-12 | A pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2485531C (en) |
-
2002
- 2002-06-12 CA CA2485531A patent/CA2485531C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2485531C (en) | 2010-02-23 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20130612 |