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
  • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
  • B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
  • B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
• • 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
  • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
  • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
  • B29C35/0277—Apparatus with continuous transport of the material to be cured
• • 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
  • B29C70/523—Pultrusion, i.e. forming and compressing by continuously pulling through a die and impregnating the reinforcement in the die
• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
  • E06B3/04—Wing frames not characterised by the manner of movement
  • E06B3/06—Single frames
  • E06B3/08—Constructions depending on the use of specified materials
  • E06B3/20—Constructions depending on the use of specified materials of plastics
  • E06B3/205—Constructions depending on the use of specified materials of plastics moulded or extruded around a core
• • 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
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
• • 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
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/001—Combinations of extrusion moulding with other shaping operations
  • B29C48/0012—Combinations of extrusion moulding with other shaping operations combined with shaping by internal pressure generated in the material, e.g. foaming
• • 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
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
  • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• • 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
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
  • B29C48/154—Coating solid articles, i.e. non-hollow articles
• • 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
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
  • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/001—Profiled members, e.g. beams, sections
  • B29L2031/003—Profiled members, e.g. beams, sections having a profiled transverse cross-section

Definitions

• This invention pertains to making building components, particularly structural members having relatively low thermal conductivity.
• reinforcement fibers are dipped into a liquid resinous bath and pulled through a die to produce the desired cross-sectional shape.
• the compressed fibers and resin are then passed through a curing die during which the temperature of the resin is raised to a temperature sufficient to initiate the cure of the resin.
• Pultrusion of lineal members having a porous glass wool core is different from traditional pultrusion processes.
• the glass wool core is not dipped into a liquid bath of resin because of the need to limit the resin to the outer edges of the glass wool core.
• the glass wool core is pulled through a die in which resin is injected at a relatively low pressure in order to apply resin only in the outer portion of the glass wool core.
• the coated lineal member is passed through a curing die which initiates curing of the resin.
• the resin is a polyester resin.
• porous core lineal material In the case of a porous core lineal material, however, the relatively dense resinous area of the lineal is merely in the periphery of the cross-sectional area, and there is not enough residual heat in the pultruded lineal member to continue the curing process to completion in the ambient conditions of the manufacturing facility. Therefore, a problem in the manufacture of porous core, resin coated lineal material is that the materials are not completely cured as they are manufactured.
• the resin material which is typically a polyester material, produces styrene gas.
• the styrene is offgassed during the curing process.
• the problem with an undercured lineal member is that when it is heated up for subsequent process steps, the styrene will continue to offgas, thereby potentially affecting later processes.
• a method for making a lineal member having a porous core comprising feeding a shaped, elongated porous core, through a resin-encasing die wherein resin is injected under pressure to encase the core, through a curing die having a cross-sectional shape coinciding with and in contact with the resin-encased lineal member, with the curing die imparting sufficient heat to the lineal member to initiate cure of the resin, and through a curing chamber which is maintained at a temperature sufficient to complete the cure of the resin without substantial contact with the lineal member.
• the present invention solves the problem of incomplete cure of the pultruded, porous core lineal member by providing a curing chamber which immediately follows the curing die and in which the lineal member is maintained at a temperature sufficient to complete the cure of the resin without substantial contact with the lineal member.
• the fact that there is no substantial contact with the lineal member means that the curing chamber does not apply significant additional drag force onto the lineal member, thereby subjecting the lineal member to breaking due to forces exceeding the tensile strength of the lineal member.
• the porous core has density less than about 320 kg/m 3 (20 lbs./ft 3 ) .
• the porous core has a density within the range of from about 96 kg/m 3 (6 lbs./ft 3 ) to about 192 kg/m 3 (12 lbs./ft 3 ) .
• the encased lineal is subjected to an additional coating step, preferably a painting step, which includes heating the encased lineal to temperature of at least 60°C (140°F) after the encased lineal is coated.
• an additional coating step preferably a painting step, which includes heating the encased lineal to temperature of at least 60°C (140°F) after the encased lineal is coated.
• the resin is injected under pressure lower than about 207 kPa (30 psi) to encase the core.
• the curing chamber applies a drag force of less than about 2.27 kg (5 lbs.) on the lineal member.
• the drag force applied by the curing chamber is less than about 0.91 kg (2 lbs.).
• FIG. 2 is a schematic cross-sectional view in elevation of the curing die, taken along line 2-2.
• FIG. 3 is a schematic cross-sectional view in elevation of the curing chamber taken along lines 3-3.
• FIG. 4 is a schematic elevational view of the lineal painting process.
• porous core 10 is pulled through various coating and curing equipment by puller 12 to form lineal member 14.
• the puller can be any mechanical device, commonly known in the art, for pulling materials in a pultrusion process.
• the porous core is preferably of mineral fibers, and most preferably is comprised of glass wool containing a resinous binder of urea phenol formaldehyde.
• the porous core is preferably less than about 320 kg/m 3 (20 lbs./ft 3 ) , and more preferably has a density within the range of from about 96 kg/m 3 (6 lbs./ft 3 ) to about 192 kg/m 3 (12 lbs./ft 3 ) .
• the density of the glass wool porous core is approximately 160 kg/m 3 (10 lbs./ft 3 ) .
• the resin coating process is generally carried out as a two stage process.
• the primer resin coat is applied first to the outer periphery of the porous core.
• Resin impregnating die 16 connected with primer resin supply 18 can be used to apply a primer coat to the porous core.
• Primer curing oven 20 can be positioned next in line in order to cure the primer resin.
• the resin impregnated porous core is then passed through the coating apparatus which is comprised of coating resin supply 22 and resin encasing die 24. In this way, the porous core is first treated with a primer resin and then treated with an outer coating resin. It is to be understood that the invention could be used with a single resin application rather than a double resin application.
• the curing die 26 Immediately following the resin encasing die is the curing die 26.
• the curing die as shown in FIG. 2, has an inner surface with a cross-sectional shape coinciding with and in contact with the resin encased lineal member.
• Curing dies are well known in the art. Typically, they are heated with a heating means, such as electric heaters 30. In a typical use of the invention, the curing die imparts sufficient heat to the lineal member to initiate cure of the resin.
• the cure initiation temperature for a polyester resin is approximately 110°C (230 ⁇ F) . Since the curing die is in close contact with the lineal member passing through it, a significant amount of drag force is applied to the lineal member.
• the lineal member As shown in FIG. 3, after the lineal member is passed through the curing die, it travels through curing chamber 32 which is maintained at a temperature substantially equal to or greater than the temperature of the resin at the exit end of the curing die.
• the heat applied to the lineal member in the curing chamber is primarily accomplished through hot air convection heat transfer.
• the hot air is supplied by any suitable heating means, such as heater 34, and driven by fan 36. It is to be understood that any other means for maintaining the temperature of the lineal member at a temperature sufficient to complete the cure can be used.
• the curing chamber must be long enough and hot enough to enable the resin to be either completely cured or sufficiently advanced in cure so that the cure will be completed in the ambient plant conditions shortly after the lineal member exits the curing chamber.
• the lineal member is supported in the curing chamber by a series of rollers, such as support rollers 38. It can be seen that the support rollers provide little, if any, substantial contact with the lineal member so that the drag force is not substantially increased. Any other suitable means for supporting the lineal member within the curing chamber can be used. It can be seen in FIG. 3 that the cross-sectional view of the lineal member shows that a substantial portion of the area is the porous core, and only a minor portion of the area is resin coating 40. Preferably, the porous portion of the cross-sectional area is at least 75% of the total cross-sectional area of the lineal member.
• the porous core portion of the lineal member is at least 85% of the total cross-sectional area of the lineal member.
• the density of the resin coating is in excess of 800 kg/m 3 (50 lbs./ft 3 ) .
• the temperature of the resin will increase while the resin passes through the curing die from a entry temperature of about 93.3 ⁇ C (200 ⁇ F) to an exit temperature of about 154°C (310°F) .
• the temperature of the hot gases in the curing chamber is preferably maintained within the range of from about 148.9"C (300 ⁇ F) to about 162.78"C (325 ⁇ F).
• Porous-cored, resin-encased lineal members are often subjected to additional process steps which involve heating the lineal to temperatures as high as 60°C (140°F) and possibly as high as 82"C (180"F) or higher.
• a subsequent process step for the lineal member is the painting process.
• the lineal member is fed through paint die 42 and subsequently passes through paint oven 44 to produce painted lineal 46.
• These processes are conventional in painting of glass fiber cored window lineals, for example. While in the paint oven, the lineal member will experience temperatures of approximately 93.3°C (200°F).
• lineal member passing through the paint oven has uncured polyester resin in the resin coating, then the resin may offgas styrene, thereby creating bubbles and other surface defects in the surface of the lineal.
• lineal members passing through a curing chamber according to the invention will have completely cured resin, and will not be subject to offgasing of styrene during a subsequent step, such as a painting process.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Health & Medical Sciences (AREA)
• Oral & Maxillofacial Surgery (AREA)
• Thermal Sciences (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Moulding By Coating Moulds (AREA)
• Application Of Or Painting With Fluid Materials (AREA)

Applications Claiming Priority (3)

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• 1993
  • 1993-09-29 WO PCT/US1993/009239 patent/WO1994007682A1/en not_active Application Discontinuation
  • 1993-09-29 EP EP93922427A patent/EP0619775A1/de not_active Withdrawn
  • 1993-09-29 JP JP6509266A patent/JPH07501996A/ja active Pending

Non-Patent Citations (1)

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