US20030003265A1 - Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof - Google Patents

Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof Download PDF

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Publication number
US20030003265A1
US20030003265A1 US10/024,337 US2433701A US2003003265A1 US 20030003265 A1 US20030003265 A1 US 20030003265A1 US 2433701 A US2433701 A US 2433701A US 2003003265 A1 US2003003265 A1 US 2003003265A1
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United States
Prior art keywords
fibers
transverse
layer
resin
part according
Prior art date
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Abandoned
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US10/024,337
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English (en)
Inventor
Laurence Davies
Mark Bamford
Rodney Isfeld
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Omniglass Ltd
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Individual
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Priority to US10/024,337 priority Critical patent/US20030003265A1/en
Assigned to OMNIGLASS LTD. reassignment OMNIGLASS LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BAMFORD, MARK ROBERT, DAVIES, LAURENCE W., ISFELD, RODNEY HERBERT
Priority to CA002390468A priority patent/CA2390468C/fr
Priority to US10/167,985 priority patent/US6746747B2/en
Priority to EP02254153A priority patent/EP1287971B1/fr
Priority to EP07075569A priority patent/EP1842657A3/fr
Priority to AT02254153T priority patent/ATE368562T1/de
Priority to DE2002621469 priority patent/DE60221469T2/de
Publication of US20030003265A1 publication Critical patent/US20030003265A1/en
Priority to US10/766,325 priority patent/US7514135B2/en
Abandoned legal-status Critical Current

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    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/083—Combinations of continuous fibres or fibrous profiled structures oriented in one direction and reinforcements forming a two dimensional structure, e.g. mats
    • 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
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
    • Y10T428/139—Open-ended, self-supporting conduit, cylinder, or tube-type article
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
    • Y10T428/24124—Fibers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249928—Fiber embedded in a ceramic, glass, or carbon matrix
    • Y10T428/249929—Fibers are aligned substantially parallel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/249928—Fiber embedded in a ceramic, glass, or carbon matrix
    • Y10T428/249929—Fibers are aligned substantially parallel
    • Y10T428/24993—Fiber is precoated
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/249942—Fibers are aligned substantially parallel
    • Y10T428/249946—Glass fiber
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
    • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
    • Y10T428/24995—Two or more layers
    • Y10T428/249952—At least one thermosetting synthetic polymeric material layer

Definitions

  • This invention relates to a pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing the part.
  • Pultrusion is a technique in which longitudinally continuous fibrous structures are used to pull a resin through a die so that the resin sets and produces a rigid part downstream of the die to which the pulling force is applied.
  • transverse fibers to provide strength in the transverse direction.
  • Such transverse fibers are conventionally applied using a mat of a woven or non woven material. In many cases the fibers in the mat are generally random so that the number of fibers extending in the transverse direction is relatively small.
  • One major problem with the mat is that it is relatively expensive and can be very expensive so that it is more than double per pound of the cost of the simple conventional rovings.
  • One direction of development has been to provide improved mats which apply more of the fibers in the transverse direction thus allowing the mat to be of reduced thickness to provide the required strength or toughness in the finished part.
  • An example of a mat tailored for pultrusion is shown in published International application PCT/WO78529A1 published Dec. 28, 2000 and assigned to Pella.
  • polyester which is a simple thermo-set resin material so that it can be applied to the fibers from a bath and is thermo-set within the heated die.
  • polyester is a linear polymer which is thus not cross-linked so that it is relatively brittle so that it tends to crack when bending forces are applied to the part.
  • This cracking is reduced by providing in the reinforcing fibers a mat material at the surface of the wall of the part so that the fibers are held in place by the transverse fibers. This avoids or reduces the tendency of the longitudinal fibers to break through the surface of the part on bending of the part.
  • polyester resin parts have required that the mat be applied on the outside surface.
  • a mat is applied on the surface of each wall of the part so that there is a mat on the outside and also a mat on the inside surface with the normal longitudinal fibers being placed in between the two mats.
  • This construction significantly increases the cost of the part in that the mat is relatively expensive and two mats are required. Also the provision of two mats increases the thickness of the part and thus again increases material costs.
  • Non-linear resins which may be cross-linked or amorphous such as epoxy have been available for some years and are used in pultrusion; but these are significantly more expensive than polyester and thus have not achieved significant market penetration in conventional simple parts for which pultrusion is ideally suited.
  • 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;
  • a non-linear resin material which may be preferably cross-linked or amorphous, permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
  • the reinforcing fibers including a first layer of fibers extending in the longitudinal pultrusion direction and located at the first surface;
  • the reinforcing fibers including a second layer of fibers extending in the longitudinal pultrusion direction and located at the second surface;
  • the reinforcing fibers including an intermediate layer of fibers at least some of which include at least portions thereof which extend in the transverse direction and located between the first and second layers;
  • 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;
  • the wall defining a peripheral wall fully surrounding a hollow interior such that the first surface faces outwardly and the second surface faces inwardly;
  • a non-linear resin material which may be preferably cross-linked or amorphous, permeated through the fibers and filling the thickness between the surfaces so as to define the surfaces;
  • the reinforcing fibers including a first layer of fibers extending in the longitudinal pultrusion direction and located at the first surface;
  • the reinforcing fibers including a transverse layer of fibers at least some of which include at least portions thereof which extend in the transverse direction and located at the second surface.
  • the resin is a urethane resin although other resins can be used provided they cross-link which allows the fibers to be located at the surface without the fibers cracking through the surface.
  • the resin is a two part material set by catalytic action and is thermo-set.
  • other resins can also be used
  • the fibers of the intermediate layer form fibers of a pre-formed mat which may be of a conventional construction defined by random continuous fibers boded or needle punched for connection.
  • the mat may also be of the construction shown in the above published International Application assigned to Pella Corporation and on which the present inventor is one of the named inventors.
  • the intermediate layer of fibers comprises a plurality of cut fibers which are unsupported by mat fibers and are applied onto the second layer of fibers to be carried thereby.
  • the intermediate layer of fibers preferably consist wholly cut fibers.
  • the intermediate layer of fibers comprises primarily and preferably wholly straight fibers extending transverse to the longitudinal direction fully across the width of the part from one side to the other side.
  • the reinforcing fibers consist only of the first layer, the second layer and the intermediate layer.
  • the transverse layer has a weight of less than 1 oz/square foot preferably less than 0.5 oz/square foot. and more preferably less than 0.25 oz/square foot since it has been found that the provision of increased amounts of fiber can interfere with the cross-linking of the resin and thus provide a decreased strength rather than the increase which would normally be expected with conventional resins.
  • the transverse layer may be a scrim or mesh having openings for penetration of the resin between the fibers so as to allow effective cross-linking of the resin. It has also been found that surprisingly a veil of staple polyester fibers having a weight of as low as 0.1 oz/square foot can provide the required additional strength and/or toughness to the product.
  • the transverse or intermediate layer may be formed of any suitable fibers including but not limited to glass fibers, carbon fibers polymer fibers such as polyester or aramids, metal strands such as aluminum or steel or natural fibers such as cotton, jute, hemp or flax.
  • Natural fibers such as flax have the advantage that they are inexpensive and are to some extent porous thus allowing the resin to enter the interstices in the fibers and providing an increased bond between the fibers and the resin which can lead to reduced de-lamination and thus increased strength.
  • Metal strands have the advantage that they provide the required additional strength and/or toughness in the intermediate layer, but also they can provide other functions such as the required ferromagnetic effect for magnetic coupling as shown for example in U.S. Pat. No. 5,129,184 (Fish) issued Jul. 14, 1992 and/or an electrostatic charging effect for electrostatic deposition of a coating or paint material.
  • the wall may include a leg portion thereof in which the reinforcing fibers consist solely of the longitudinal fibers, that is there is no transverse fibers.
  • the leg such as a glazing leg of a window profile has a length greater than 0.5 inches which would normally require transverse reinforcement but a length less than about 1.0 inches where there is insufficient bending moment in the leg itself to allow cracking in the leg to occur.
  • the bending effect at an angle is different from that within a span of the material.
  • the provision of transverse fibers within a leg or span of greater than 1.0 inches in length is required while such fibers are not necessary at an angle between two legs of shorter length.
  • the leg portion may have a wall that is thicker than that of the main body portion; but this is provided for balancing of forces in the pultrusion process rather than in order to provide increased strength to compensate for the absence of the mat or transverse fibers.
  • the main body portion defines a hollow section and the leg portion, generally a glazing leg, extends from one end at the hollow section to an opposed free end.
  • the urethane resin used preferably in the embodiments described hereinafter has the advantage that it is more resistant to degradation by UV and weather so that it is more suitable for fenestration products.
  • the construction described in the embodiments hereinafter also may have the advantage that it allows a reduced wall thickness.
  • the use, in lower strength products such as fenestration products, conventionally of two outside perimeter mats can be reduced by one mat to one mat so that the total thickness can be reduced by at least 0.015 inch, which is the typical thickness of one mat.
  • the increased strength in the resin itself may allow a further reduction so that typically a conventional range in inches of polyester resin construction of 0.070 to 0.180 for different end uses can be reduced to a range of 0.030 to 0.120.
  • a thickness even as low as 0.025 may also be possible for products such as fenestration products which require lower structural strength and a thickness of the order of 0.080 may be possible for products such as ladder rails or tool handles which require higher structural strength.
  • the higher strength structural products often include a third mat along the center and thus the three mats of the conventional product can be reduced to one mat or veil in the arrangement described above thus yet further reducing the thickness.
  • This reduction in mat content also increases the proportion of longitudinal fibers or rovings and this also has the advantage that the longitudinal stiffness of the part as provided by the longitudinal fibers is also increased.
  • a ladder rail may be reduced typically in thickness from 0.125 to 0.105 inch with an increase in strength.
  • the transverse fibers are formed of metal strands which provide both transverse strength and the characteristic of electrical conductivity and/or ferromagnetism for the part.
  • FIG. 1 is a cross sectional view of typical pultruded part according to to the present invention.
  • FIG. 2 is a cross sectional view on an enlarged scale of one wall of the part of FIG. 1, the cross section being at right angles to that of FIG. 1.
  • FIG. 3 is a cross sectional view on an enlarged scale of one wall of the part of FIG. 1.
  • FIG. 4 is a schematic side elevational view of a method according to the present invention for manufacturing the part of FIG. 1.
  • FIG. 5 is a top plan view of the method of FIG. 4.
  • FIG. 6 is a top plan view of an alternative arrangement of the intermediate layer of the method of FIG. 4.
  • FIG. 7 is a cross sectional view on an enlarged scale of an alternative construction of the fiber reinforcement used in the part shown in FIG. 1.
  • FIG. 8 is a first graph showing the comparative strength and modulus of a series of coupon samples as set out in table 1 based upon standard test ASTM D790.
  • FIG. 9 is a second graph showing the comparative strength of a series of angle samples as set out in table 1 with the test being entitled modified Lip Test.
  • FIG. 10 is a second graph showing the comparative strength of a series of angle samples as set out in table 2 with the test being entitled modified Lip Test 2 .
  • Table 1 is a list of the materials tested in FIGS. 8 and 9.
  • FIG. 1 a typical cross section of a pultruded part which includes a hollow section 10 , a leg 11 and a projecting portion 12 .
  • the hollow section 10 includes four wails 10 A, 10 B, 10 C and 10 D each of which has a thickness between an outer surface 10 E and an inner surface 10 F.
  • each wall part of the pultrusion must be manufactured in a manner which provides the necessary strength to prevent cracking of the part.
  • FIGS. 2 and 3 a cross section of one wall of the part which is cut to form an end face 13 .
  • the wall of the part is formed from a resin 14 which is shaped to define the surfaces 10 E and 1 OF and a volume of the part is defined by a resin material 15 which is interspersed between or permeated through fiber reinforcement 15 within the part.
  • the fiber reinforcement includes a first layer 16 of longitudinally extending fibers, primarily rovings, a second layer 17 also of longitudinally extending rovings and an intermediate layer 18 of fibers arranged to provide transverse strength.
  • the resin which extends through the part so that it defines the two surfaces of the part is a urethane resin available from Resin Systems Inc. of Edmonton, Alberta and is defined by a two-part resin which includes a catalyst for activating the resin.
  • the particularly preferred resin is known as Version G available from the above company which has the following characteristics:
  • Version G provides an ideal VOC free high performance two-component polyurethane system for use in composite manufacturing. Version G exhibits physical properties that meet or exceed those of existing products—whether commodity polyesters, or specialty resins.
  • Version G resin system is a general purpose thermosetting resin designed specifically for the composites pultrusion process. Version G is based on urethane chemistry, has been shown to provide excellent composite properties, including superior toughness, shear strength and resistance to cracking.
  • Version G resin system is formulated to be a direct replacement for existing polyester or epoxy resins. In most cases, the existing pultrusion dies, heaters and control systems can be used with relevant minor modification for optimisation of processing. Version G shows excellent physical properties when used with glass fiber sizing of the “polyester and vinyl ester ” type.
  • Version G is a two-component resin that must be used with a resin injection system.
  • the resin components may be mixed in a suitable ratio, for example 1:1, by a standard static mixer placed prior to the injection port.
  • a simple injection chamber made from for example UHMW PE, material may be added to the entrance end of the die.
  • the resin system has been shown to work with both high pressure and low pressure injection systems.
  • Version G may be used directly as a “neat” system, or it may be provided with fillers for cost reduction or property enhancement.
  • the Version G may work with a recycled rubber crumb filler system, which combines synergistically with the urethanes to enhance toughness and crack resistance properties or may use a more conventional calcium carbonate filler material.
  • FIGS. 4 and 5 is shown schematically a method for using the resin for application to the reinforcing fibers to form the part of FIG. 1.
  • the longitudinal fibers 16 are supplied from roving bobbins 16 A to define a layer of the rovings arranged substantially side by side which are carried forwardly through the pre-shaper 20 and the resin injection system 21 into the die 22 by a pulling system schematically indicated at 23 downstream of the die.
  • the layer 16 forms a band, it can act as a conveyor carrying fibers forming the intermediate layer 18 into the same elements for forming the pultruded part.
  • the intermediate layer 18 is covered by the upper layer 17 again formed from rovings supplied from roving bobbins 17 A thus the intermediate fibers are protected and encapsulated as they are carried into the pultrusion system between the two layers 16 and 17 .
  • the pre-shaper 20 can therefore be of a simple construction which causes the band defined by the three layers to be shaped into the required shape to enter into the die to form the construction shown in cross section in FIG. 1.
  • the construction of the pre-shaper will be well known to one skilled in the art and therefore does not require detailed explanation here.
  • the resin injection arrangement is designed for use with the two-part Version G resin material described above and therefore there are two supplies supply 1 and supply 2 which are pumped from a container via two separate pumps into a mixer immediately upstream of the resin injection system. The materials are therefore mixed for only a short period of time before the resin is injected into the dry fibers so as to permeate through the fibers and to be carried by the fibers into the die.
  • the details of the mixer valve and the resin injection system are again well known to one skilled in the art and provide the necessary controls for varying the mix proportions and for ensuring that the required amount of resin is maintained within the injection system.
  • the transverse fiber layer 18 is protected within in the two layers 16 and 17 , it is possible to supply the transverse fiber layer either as a pre-formed mat or as individual chopped fibers. Pre-form mat is relatively expensive since it involves an additional process and this may double or triple the base material costs.
  • a cut fiber supply device 25 which receives fibers from yarn or roving supplies 26 and chops those fibers into fiber strands 27 laid across the width of the layer 16 defined by the rovings 16 A. These fibers can thus be laid loosely across the layer 16 since they will be covered by the layer 17 supplied from the rovings 17 A at a guide roller R.
  • the fibers of the intermediate layer can be added by mixing cut fibers with the resin material and injecting the resin between the roving layers so that the resin permeates through the roving layers while leaving the cut fibers between the rovings.
  • Such cut fibers can be introduced to the resin during the mixing stage and can pass through the pump with the resin into the die block as described herein.
  • the rovings carry the cut fibers, or other fibers of the intermediate layer however they are introduced, there is no problem of the intermediate layer skewing as it enters the die and no requirement therefore for anti-skewing arrangements within the intermediate layer. It will be appreciated that the application of cut fibers has significantly less structural stability than even the thin mats and veils described herein and yet even these cut fibers can be introduced without skewing or other breakdown of the layer becoming a problem.
  • the intention is therefore to provide fibers which extend with their direction primarily or wholly across the width of the layer 16 so as to avoid the necessity for additional fiber elements within the layer 18 which do not contribute to the transfer strength.
  • the supply element 25 therefore forms in effect a gun which fires the fibers onto the layer 16 but without sufficient force to disturb the layer 16 .
  • Conventional chopping guns can be used for this purpose or a gun can be designed which fires the fibers across the width of the layer 16 so that they are cut only when they reach across the full width thus laying them across the full width as shown in FIG. 5.
  • the intermediate layer is formed simply from a mat pre-formed using conventional materials.
  • the fibers of the intermediate layer can be formed from glass using relatively thick or coarse fibers for strength or can be fine glass fibers of the type normally formed to provide a veil.
  • the coarse fibers would normally have a weight less than 1 ounce per square foot. Other such mats may have a weight of the order of 0.5 ounces per square foot.
  • the lightweight veil material formed of fine glass fibers generally has a weight of the order of 0.25 ounces per square foot.
  • An alternative material which can be used is a polyester veil material which is formed by staple fibers of fine polyester in a mat which can be heat bonded using high and low melt fibers in the polyester mat.
  • a mat may have a weight of the order of 30 grams per square meter which is equal to 0.1 ounces per square foot approximately.
  • FIG. 8 is shown a graph of the results from a first series of different trials of materials 1 to 8 shown in table 1. The results are based upon a standard ASTM coupon test identified as ASTM D790:
  • FIG. 9 a table of results from a second series of different trials of the same materials from table 1. The results are based upon test of right angle pieces formed from the materials set out in Table 1 where the strength to break was determined by bending the angle piece in a direction to increase the angle from the nominal 90 degrees to breaking of the part. It will be noted that materials 9 and 10 in Table 1 were not used in the tests of FIG. 8.
  • FIG. 10 is shown a table of results from a series of trials of the materials from identified at the bottom of the figure. The results are based upon test of right angle pieces where the strength to break was determined by bending the angle piece in a direction to increase the angle from the nominal 90 degrees to breaking of the part.
  • polyyester are of a conventional nature using the conventional resin.
  • Those marked “RSI” use the resin of the present invention. Where a percentage is given, this relates to the percentage of filler material.
  • “ 920 ” “Nico” and “OCF” all relate to particularly types of mat as explained hereinbefore.
  • the wall width such as the walls 10 A and 10 B in FIG. 7 have a greater width which can be as much as 2 to 3 inches, it is necessary to provide the transverse fibers to provide the necessary strength against fracturing during bowing of the wall.
  • the thickness of the leg may increased so that it is at least 10% thicker and may be as much as approximately double the thickness of the walls 10 A and 10 B.
  • the structure can de-laminate under inter-laminar shear at the transverse fibers when bending particularly at a junction for example between the leg 11 and the wall 10 A.
  • the arrangement of the present invention preferably uses a minimum quantity of transverse fibers which are necessary to provide for the resin the increase in strength for the walls 10 A and 10 B to match conventional strengths. This reduces the tendency to de-laminate under inter-laminar shear which could otherwise occur where thicker layers of transverse fibers or mats and used.
  • the mat layer indicated at 18 N is located on the inside surface of each of the walls 10 A, 10 B, etc.
  • the mat forms the innermost layer and the remainder of the wall is reinforced by the conventional longitudinal fibers indicated at 17 N.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Laminated Bodies (AREA)
US10/024,337 2001-06-14 2001-12-21 Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof Abandoned US20030003265A1 (en)

Priority Applications (8)

Application Number Priority Date Filing Date Title
US10/024,337 US20030003265A1 (en) 2001-06-14 2001-12-21 Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof
CA002390468A CA2390468C (fr) 2001-06-14 2002-06-12 Piece pultrudee renforcee par des fibres longitudinales et transversales et methode de fabrication
US10/167,985 US6746747B2 (en) 2001-06-14 2002-06-13 Pultruded part reinforced by longitudinal and transverse fibers
EP02254153A EP1287971B1 (fr) 2001-06-14 2002-06-13 Pièce pultrudée renforcée par des fibres longitudinales et transversales
EP07075569A EP1842657A3 (fr) 2001-06-14 2002-06-13 Pièce pultrudée renforcée par des fibres longitudinales et transversales et procédé pour la fabriquer
AT02254153T ATE368562T1 (de) 2001-06-14 2002-06-13 Durch längs- und querrfasern verstärktes, pultrudiertes teil
DE2002621469 DE60221469T2 (de) 2001-06-14 2002-06-13 Durch Längs- und Querrfasern verstärktes, pultrudiertes Teil
US10/766,325 US7514135B2 (en) 2001-06-14 2004-01-29 Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof

Applications Claiming Priority (2)

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US32578501P 2001-06-14 2001-06-14
US10/024,337 US20030003265A1 (en) 2001-06-14 2001-12-21 Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof

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US10/167,985 Continuation-In-Part US6746747B2 (en) 2001-06-14 2002-06-13 Pultruded part reinforced by longitudinal and transverse fibers
US10/766,325 Continuation-In-Part US7514135B2 (en) 2001-06-14 2004-01-29 Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof

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US10/167,985 Expired - Fee Related US6746747B2 (en) 2001-06-14 2002-06-13 Pultruded part reinforced by longitudinal and transverse fibers

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US20020123288A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Pultruded part with reinforcing mat
US20020121722A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Method of making a pultruded part with a reinforcing mat
US20020123287A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Reinforcing mat for a pultruded part
US6881288B2 (en) 1999-06-21 2005-04-19 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20070117921A1 (en) * 2005-11-23 2007-05-24 Milgard Manufacturing Incorporated Resin for composite structures
US20070116941A1 (en) * 2005-11-23 2007-05-24 Milgard Manufacturing Incorporated Pultruded component
US8101107B2 (en) 2005-11-23 2012-01-24 Milgard Manufacturing Incorporated Method for producing pultruded components
US8597016B2 (en) 2005-11-23 2013-12-03 Milgard Manufacturing Incorporated System for producing pultruded components
US8859089B2 (en) 2010-06-22 2014-10-14 Ticona Llc Reinforced hollow profiles
US9096000B2 (en) 2010-06-22 2015-08-04 Ticona Llc Thermoplastic prepreg containing continuous and long fibers
US9238347B2 (en) 2010-06-11 2016-01-19 Ticona Llc Structural member formed from a solid lineal profile
US9409347B2 (en) 2010-06-22 2016-08-09 Ticona Llc Method for forming reinforced pultruded profiles
CN108396644A (zh) * 2017-12-18 2018-08-14 河北恒瑞复合材料有限公司 一种smc复合材料及使用该材料的人行道系统
US11813810B2 (en) * 2017-08-14 2023-11-14 Zephyros, Inc. Induction heating of composite parts

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US7514135B2 (en) * 2001-06-14 2009-04-07 Omniglass Ltd. Pultruded part reinforced by longitudinal and transverse fibers and a method of manufacturing thereof
US7461437B2 (en) * 2004-11-15 2008-12-09 Velcro Industries B.V. Articles and methods of their formation
US8632708B2 (en) * 2006-02-21 2014-01-21 Werner Co. Fiberglass reinforced plastic products having increased weatherability, system and method
CA2569225C (fr) * 2006-11-09 2012-10-09 Omniglass Ltd. Joint en coin pour encadrement de fenetre pultrude
US9879440B2 (en) * 2006-10-11 2018-01-30 Nov North America I/P, Llc Fiber reinforced resin polymer mortar pole
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GB2448363A (en) * 2007-04-13 2008-10-15 3M Innovative Properties Co Tubular support of composite material
US8863454B2 (en) * 2008-11-14 2014-10-21 Omniglass Sct Inc. Pultruded part for use as a frame member for an exterior wall construction for a building
CA2644212A1 (fr) 2008-11-14 2010-05-14 Laurence W. Davies Piece pultrudee servant d'element de cadre pour construction murale exterieure de batiment
DE102009053947B4 (de) 2009-11-19 2020-02-27 Dr. Ing. H.C. F. Porsche Aktiengesellschaft Verfahren zum Herstellen von Bauteilen
US20170305078A1 (en) * 2016-04-20 2017-10-26 Fpinnovations Method for producing continuous composite sandwich structures by pultrusion
RU2738606C1 (ru) * 2020-04-08 2020-12-14 Автономная некоммерческая образовательная организация высшего образования «Сколковский институт науки и технологий» Термопластичный армированный пултрузионный профиль
WO2022213132A1 (fr) * 2021-04-02 2022-10-06 Creative Pultrusions, Inc. Éléments de compression

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US8025754B2 (en) 1999-06-21 2011-09-27 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20020121722A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Method of making a pultruded part with a reinforcing mat
US20020123287A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Reinforcing mat for a pultruded part
US6872273B2 (en) 1999-06-21 2005-03-29 Pella Corporation Method of making a pultruded part with a reinforcing mat
US6881288B2 (en) 1999-06-21 2005-04-19 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20050167030A1 (en) * 1999-06-21 2005-08-04 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20020123288A1 (en) * 1999-06-21 2002-09-05 Pella Corporation Pultruded part with reinforcing mat
US9249532B2 (en) 1999-06-21 2016-02-02 Pella Corporation Method of making a reinforcing mat for a pultruded part
US7276132B2 (en) 1999-06-21 2007-10-02 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20080053596A1 (en) * 1999-06-21 2008-03-06 Pella Corporation Method of making a reinforcing mat for a pultruded part
US8927086B2 (en) 1999-06-21 2015-01-06 Pella Corporation Method of making a reinforcing mat for a pultruded part
US20070117921A1 (en) * 2005-11-23 2007-05-24 Milgard Manufacturing Incorporated Resin for composite structures
US20070116941A1 (en) * 2005-11-23 2007-05-24 Milgard Manufacturing Incorporated Pultruded component
US8101107B2 (en) 2005-11-23 2012-01-24 Milgard Manufacturing Incorporated Method for producing pultruded components
US8519050B2 (en) 2005-11-23 2013-08-27 Milgard Manufacturing Incorporated Resin for composite structures
US8597016B2 (en) 2005-11-23 2013-12-03 Milgard Manufacturing Incorporated System for producing pultruded components
US7875675B2 (en) 2005-11-23 2011-01-25 Milgard Manufacturing Incorporated Resin for composite structures
US7901762B2 (en) 2005-11-23 2011-03-08 Milgard Manufacturing Incorporated Pultruded component
US9919481B2 (en) 2010-06-11 2018-03-20 Ticona Llc Structural member formed from a solid lineal profile
US9238347B2 (en) 2010-06-11 2016-01-19 Ticona Llc Structural member formed from a solid lineal profile
US9096000B2 (en) 2010-06-22 2015-08-04 Ticona Llc Thermoplastic prepreg containing continuous and long fibers
US9409347B2 (en) 2010-06-22 2016-08-09 Ticona Llc Method for forming reinforced pultruded profiles
US8859089B2 (en) 2010-06-22 2014-10-14 Ticona Llc Reinforced hollow profiles
US11813810B2 (en) * 2017-08-14 2023-11-14 Zephyros, Inc. Induction heating of composite parts
CN108396644A (zh) * 2017-12-18 2018-08-14 河北恒瑞复合材料有限公司 一种smc复合材料及使用该材料的人行道系统

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Publication number Publication date
ATE368562T1 (de) 2007-08-15
DE60221469T2 (de) 2008-05-21
EP1287971A3 (fr) 2003-06-18
CA2390468C (fr) 2005-04-12
US6746747B2 (en) 2004-06-08
CA2390468A1 (fr) 2002-12-14
US20030026943A1 (en) 2003-02-06
DE60221469D1 (de) 2007-09-13
EP1287971B1 (fr) 2007-08-01
EP1287971A2 (fr) 2003-03-05

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