IPC분류정보
| 국가/구분 |
United States(US) Patent
등록
|
| 국제특허분류(IPC7판) |
|
| 출원번호 |
US-0287140
(2005-11-23)
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| 등록번호 |
US-8101107
(2012-01-24)
|
|
발명자
/ 주소 |
- Brown, Randall Jay
- Kharchenko, Semen
- Coffee, Harry D.
- Huang, Icheng
|
| 출원인 / 주소 |
- Milgard Manufacturing Incorporated
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| 대리인 / 주소 |
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| 인용정보 |
피인용 횟수 :
5 인용 특허 :
222 |
초록
▼
A method for producing a pultruded component includes providing a plurality of fiber tows each formed of a plurality of fibers. The method also includes providing a first chamber and a second chamber for wetting the plurality of fiber tows with a polymeric resin precursor. The method further include
A method for producing a pultruded component includes providing a plurality of fiber tows each formed of a plurality of fibers. The method also includes providing a first chamber and a second chamber for wetting the plurality of fiber tows with a polymeric resin precursor. The method further includes pulling the plurality of fiber tows through a first chamber to wet their exterior surfaces with the polymeric resin precursor, pulling the plurality of fiber tows through a second chamber to wet the plurality of fibers within each tow, and pulling the wetted plurality of tows and fibers through a curing die to form the pultruded component.
대표청구항
▼
1. A method for producing a pultruded component comprising: providing a plurality of fiber tows, each of the plurality of fiber tows comprising a plurality of fibers;providing a first chamber and a second chamber for wetting the plurality of fiber tows with a polymeric resin precursor, the first cha
1. A method for producing a pultruded component comprising: providing a plurality of fiber tows, each of the plurality of fiber tows comprising a plurality of fibers;providing a first chamber and a second chamber for wetting the plurality of fiber tows with a polymeric resin precursor, the first chamber comprising a wall having a plurality of apertures that extend through the wall between an exterior surface of the chamber and an interior surface of the chamber that is in contact with the polymeric resin precursor so that fiber tows passing through the apertures immediately contact the polymeric resin precursor upon exiting the apertures;pulling the plurality of fiber tows through the wall and the first chamber to wet their exterior surfaces with the polymeric resin precursor, wherein pulling the plurality of fiber tows through the first chamber comprises pulling the plurality of fiber tows through a bath of the polymeric resin precursor prior to entering the second chamber;pulling the plurality of fiber tows through the second chamber to wet the plurality of fibers within each tow, the second chamber tapered substantially along its entire length; andpulling the wetted plurality of tows and fibers through a curing die to form the pultruded component, wherein the curing die is in contact with the second chamber;wherein the fiber tows are continuously pulled through the first chamber, the second chamber, and then the curing die at a substantially constant rate. 2. The method of claim 1, wherein the polymeric resin precursor is a thermosetting polyurethane resin precursor. 3. The method of claim 1, wherein the first chamber is provided in contact with the second chamber. 4. The method of claim 1, further comprising providing the polymeric resin precursor to the first chamber at a rate that matches the consumption of the polymeric resin precursor. 5. The method of claim 1, wherein the second chamber is tapered from an entrance of the second chamber to an exit of the second chamber. 6. The method of claim 1, wherein the second chamber is configured to allow penetration of the polymeric resin precursor into the fiber tows by capillary action. 7. The method of claim 1, further comprising pulling the plurality of fiber tows through the wall before pulling the fiber tows through the first chamber, wherein the step of pulling the fiber tows through the wall acts to separate the fiber tows from adjacent fiber tows to allow the polymeric resin precursor to flow around the fiber tows. 8. The method of claim 1, further comprising pulling the fiber tows through a curing die after pulling the fiber tows through the first chamber and the second chamber. 9. The method of claim 1, wherein the fiber tows each comprise a plurality of glass fibers. 10. A method for producing pultruded products comprising: providing a plurality of fiber tows, each of the fiber tows comprising a plurality of filaments;separating the plurality of fiber tows a sufficient distance to allow resin precursor to flow around the fiber tows;pulling the fiber tows through an impregnation die having a first zone and a second zone, the first zone configured for wetting an external surface of the fiber tows with a polyurethane resin precursor and the second zone configured for wetting the plurality of filaments in the fiber tows with the polyurethane resin precursor, wherein the first zone comprises a wall having apertures formed therein and the fiber tows contact the polyurethane resin precursor immediately upon exiting the apertures; andpulling the fiber tows through a curing die to cure the polyurethane resin precursor wherein the curing die is in contact with the impregnation die;wherein the second zone has a cross-sectional area that decreases from its entrance to its exit;wherein the first zone is provided as an atmospheric pressure bath in fluid communication with the second zone;wherein the fiber tows are continuously pulled through the first and second zones and the curing die at a substantially constant rate. 11. The method of claim 10, further comprising preparing the polyurethane resin precursor in parallel with the step of pulling the fiber tows through the impregnation die. 12. The method of claim 11, wherein the step of preparing the polyurethane resin precursor comprises mixing a first component with a second component, the first component comprising a first reactive material and a plurality of additives and the second component comprising a second reactive material. 13. The method of claim 10, wherein the step of separating the plurality of fiber tows comprises pulling the fiber tows through a backing plate having a plurality of holes formed therein. 14. The method of claim 13, wherein the holes have a size sufficient to allow passage of spliced yarns of fiber. 15. The method of claim 10, wherein the first zone is configured to receive the polymeric resin precursor at atmospheric pressure from a mixing system. 16. The method of claim 10, wherein the step of providing the fiber tows comprises unwinding the fiber tows from a creel that includes a plurality of spindles. 17. A method of producing a composite structural component comprising: providing fiber tows comprising a plurality of fibers;providing a device having a first chamber for wetting an external surface of the fiber tows with a polymeric resin precursor, a second chamber for wetting the plurality of fibers within each of the fiber tows, and a curing die in contact with the second chamber, wherein the first chamber comprises a wall in contact with the polymeric resin precursor, the wall having apertures through which the fiber tows are pulled such that the fibers enter the polymeric resin precursor immediately upon exiting the apertures;preparing the polymeric resin precursor;pulling the fiber tows through the device; andmixing and providing the polymeric resin precursor to the first chamber at a rate that substantially matches the rate of consumption of the polymeric resin precursor;wherein the first chamber is provided as an atmospheric pressure bath;wherein the fiber tows are pulled through the first chamber, second chamber, and curing die at a substantially constant rate. 18. The method of claim 17, wherein the step of preparing the polymeric resin precursor comprises mixing at least two components of the polymeric resin precursor within five minutes of providing the polymeric resin precursor to the first chamber. 19. The method of claim 18, wherein the polymeric resin precursor is a polyurethane resin precursor. 20. The method of claim 17, wherein the first chamber is in contact with the second chamber. 21. The method of claim 17, further comprising separating the fiber tows from each other by a distance selected to allow the polymeric resin precursor to flow around the fiber tows before pulling the fiber tows through the device. 22. The method of claim 17, wherein the second chamber tapers from a first end through which the fiber tows enter the second chamber to a second end through which the fiber tows exit the second chamber. 23. The method of claim 17, further comprising curing the polymeric resin precursor. 24. The method of claim 17, wherein the step of providing the fiber tows comprises unwinding the fiber tows from a creel. 25. The method of claim 1, further comprising passing the plurality of fiber tows through a forming card before pulling the plurality of fiber tows through the wall of the first chamber, the forming card comprising apertures configured to arrange the tows in a desired shape. 26. The method of claim 10, further comprising pulling the plurality of fiber tows through a forming card prior to pulling the plurality of fiber tows through the impregnation die, the forming card being spaced away from the wall of the first zone. 27. The method of claim 17, further comprising arranging the fiber tows in a desired shape prior to pulling the fiber tows through the device. 28. The method of claim 27, wherein the step of arranging the fiber tows in a desired shape prior to pulling the fiber tows through the device comprises pulling the fiber tows through a supporting fixture having apertures therein. 29. The method of claim 1, wherein the curing die includes an entrance taper to provide compression pressure to the wetted plurality of tows and fibers. 30. The method of claim 1, wherein the curing die includes an exit taper. 31. The method of claim 1, wherein the curing die is heated by electric resistance heaters. 32. The method of claim 1, wherein the curing die is heated in a plurality of zones. 33. The method of claim 1, wherein the curing die is heated to different temperatures between an entrance and an exit of the curing die. 34. The method of claim 1, further comprising a cooling system provided at an entrance and an exit of the curing die. 35. The method of claim 10, wherein the curing die includes an entrance taper and an exit taper and is heated by electric resistance heaters. 36. The method of claim 10, wherein the curing die is heated to different temperatures between an entrance and an exit of the curing die. 37. The method of claim 10, further comprising a cooling system provided at an entrance and an exit of the curing die. 38. The method of claim 17, wherein the curing die includes an entrance taper and an exit taper and is heated by electric resistance heaters such that the curing die is heated to different temperatures between an entrance and an exit of the curing die. 39. The method of claim 17, further comprising a cooling system provided at an entrance and an exit of the curing die. 40. The method of claim 1, wherein the second chamber has a longer length than the first chamber. 41. The method of claim 1, wherein the first and second chambers have a combined length of no more than approximately 15 inches.
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