Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1989-10-17
1992-06-09
Woo, Jay H.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156180, 156441, 264137, 264510, 264518, 425 831, 425114, B29C 6714
Patent
active
051203804
DESCRIPTION:
BRIEF SUMMARY
This invention relates to in-line core-filled pultruded profiles.
It is well known that pultrusion is an effective method of producing constant cross-section profiles by a continuous process. Known profiles are mostly made of resin-bonded glass fiber rovings but where additional strength is required some or all of the glass fiber rovings may be replaced with carbon or aramid fiber rovings. Typically the rovings are unwound from cones (or cheeses) mounted on a frame and individually fed via guides to the inlet of a die station so that the rovings occupy the cross-sectional area of the die. Bonding resin is injected into the die to wet the rovings which are then transported through a curing die where the resin cures to provide a rigid resin bonded profile. Most profiles have standard cross-sectional shapes such as L, U, T, O. Hollow section profiles have also been manufactured and cored in a secondary process by injection of polyurethane or polyisocyanurate type foams. Precise core packing in complex pultruded profiles is difficult to achieve, and shrinkage in the core foam when processed creates bonding difficulties, resulting in a high percentage of rejects. More recently there has been proposed in U.K. patent specification No. 2160143A a method of manufacturing in-line core-filled pultruded profiles in which the rovings which form a skin in the profile are fed to the die station at the same time as but separately from particulate filler, the latter being a combination of coarse and fine granulates delivered to the die station by vacuum applied at the die station.
It is an object to provide a new and improved system of manufacturing pultruded profiles and new and improved pultruded profiles.
According to the present invention there is provided a system of manufacturing pultruded profiles having a core resin-bonded to a skin, comprising separately feeding core-forming materials and skin-forming materials to the inlet of a pultrusion die station which includes a resin-curing die having a cross-sectional shape for determining the cross-sectional shape of the profile, the core-forming materials being delivered to the die station inlet through a hollow duct and the skin-forming materials being delivered exteriorly of the duct to the die station inlet, introducing bonding resin to said station, and pulling from the outlet of said station an in-line cored resin-bonded profile, characterized in that the hollow duct is elongate and is provided with an external shape which progressively along its length conforms to the cross-sectional shape of the resin-curing die and at the die station end is similar in cross-section but oversize in relation to that of the resin-curing die, the skin-forming materials comprising at least one run of cloth which is guided over the outer surface of the duct so as progressively to conform to the cross-sectional shape of the resin-curing die as the cloth run approaches the die station.
Further according to the present invention there is provided a pultruded profile having a core resin-bonded to a skin, the skin comprising resin-impregnated cloth.
By virtue of the present invention because the skin-forming materials comprise at least one run of cloth, fiber rovings are reduced or eliminated with consequential reduction or elimination of the very substantial labour and time required to monitor and handle cones (or cheeses) which, even for simple profiles are extensive in number. The use of cloth when woven also imparts a two-dimensional strength to the profile in comparison to the one dimensional strength imparted by rovings. The use of cloth is rendered practical by the presence of the externally profiled former duct in advance of the die station.
Preferably the core-forming materials comprise particulate matter blown through the duct towards the die station by an air stream which is at least partly diffused outwardly through the cloth prior to the resin-curing die. This arrangement contributes to good packing of the particulate matter in the profile.
Preferably also the air stream is pro
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patent: 4115498 (1978-09-01), Kissell et al.
patent: 4166090 (1979-08-01), Green et al.
patent: 4891179 (1990-01-01), Peacock et al.
Caledonia Composites Limited
Davis Robert B.
Woo Jay H.
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