CA2514178A1 - Method and apparatus for manufacturing a reinforcement - Google Patents
Method and apparatus for manufacturing a reinforcement Download PDFInfo
- Publication number
- CA2514178A1 CA2514178A1 CA002514178A CA2514178A CA2514178A1 CA 2514178 A1 CA2514178 A1 CA 2514178A1 CA 002514178 A CA002514178 A CA 002514178A CA 2514178 A CA2514178 A CA 2514178A CA 2514178 A1 CA2514178 A1 CA 2514178A1
- Authority
- CA
- Canada
- Prior art keywords
- resin
- fibers
- reinforcement
- manufacturing
- structural member
- 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.)
- Abandoned
Links
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]
- B29C70/504—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] using rollers or pressure bands
-
- 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
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
Abstract
A method includes wetting fibers with a resin capable of being cured by at least two different cure treatments. At least partially curing the resin by subjecting the resin to a first cure treatment (36) and at least partially curing the resin by subjecting the resin to a second cure treatment. A
plurality of fibers are located adjacent each other so that a plurality of valleys (34) are formed between the plurality of fibers along an outer side of the reinforcement. The resin is cured to retain the valleys in the outer side of the reinforcement. The outer side of the reinforcement is adhered to the structural member (44). An apparatus including a fiber locating mechanism adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement.
plurality of fibers are located adjacent each other so that a plurality of valleys (34) are formed between the plurality of fibers along an outer side of the reinforcement. The resin is cured to retain the valleys in the outer side of the reinforcement. The outer side of the reinforcement is adhered to the structural member (44). An apparatus including a fiber locating mechanism adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement.
Description
METHOD AND APPARATUS FOR MANUFACTURING A REINFORCEMENT
FIELD OF THE INVENTION
[0001] The present invention relates to composite fiber and resin reinforcements for structural members; and more particularly, to methods of manufacturing such fiber reinforcements.
BACKGROUND OF THE INVENTION
[0002] Reinforcements for structural members have been manufactured using pultrusion processes. This process generally involves wetting fibers with resin and pulling them through a mold where the resin is cured as a result of heating the resin. The mold tends to create relatively smooth surfaces on the sides of the reinforcement although some recesses are often present. Exemplary pultrusion processes are disclosed, for example, in the following patents: U.S. Patent No. 3,895,896 which issued to White et al.
on July 22, 1975; U.S. Patent No. 5,286,320 which issued to McGrath et al. on February 15, 1994; U.S. Patent No. 5,374,385 which issued to Binse et al. on December 20, 1994; U.S. Patent No. 5,424,388 which issued to Chen et al. on June 13, 1995; U.S. Patent No. 5,556,496 which issued to Sumerak on September 17, 1996; U.S. Patent No. 5,741,384 which issued to Pfeiffer et al.
on April 21, 1998; and U.S. Patent No. 5,783,013 which issued to Beckman et al. on July 21, 1998.
FIELD OF THE INVENTION
[0001] The present invention relates to composite fiber and resin reinforcements for structural members; and more particularly, to methods of manufacturing such fiber reinforcements.
BACKGROUND OF THE INVENTION
[0002] Reinforcements for structural members have been manufactured using pultrusion processes. This process generally involves wetting fibers with resin and pulling them through a mold where the resin is cured as a result of heating the resin. The mold tends to create relatively smooth surfaces on the sides of the reinforcement although some recesses are often present. Exemplary pultrusion processes are disclosed, for example, in the following patents: U.S. Patent No. 3,895,896 which issued to White et al.
on July 22, 1975; U.S. Patent No. 5,286,320 which issued to McGrath et al. on February 15, 1994; U.S. Patent No. 5,374,385 which issued to Binse et al. on December 20, 1994; U.S. Patent No. 5,424,388 which issued to Chen et al. on June 13, 1995; U.S. Patent No. 5,556,496 which issued to Sumerak on September 17, 1996; U.S. Patent No. 5,741,384 which issued to Pfeiffer et al.
on April 21, 1998; and U.S. Patent No. 5,783,013 which issued to Beckman et al. on July 21, 1998.
[0003] Another type of pultrusion process has involved spreading resin on a film such as Mylar, adding fiber materials, and then adding a top cover film to form an envelope that essentially becomes a flexible mold. This sandwich is shaped by tension and mechanical forms and is then pulled through an oven to cure the sandwich in the form that is desired.
[0004] A third variation of pultrusion provides for the fibers to be placed under tension, saturated with photo-initiated resin, pulled through a series of sized dies to form the fibers into a round bundle, and then exposed to high intensity ultraviolet light where curing is initiated. A surface coating is then applied and cured to provide a desired resin rich surface. This process has been used in forming strengthening members of fiber optic cables. Exemplary variations of this process are disclosed in U.S. Patent No. 4,861,621 which issued to Kanzaki on August 29, 1989; and U.S. Patent No. 5,700,417 which issued to Fernyhough et al. on December 23, 1997.
[0005] A forth variation of pultrusion provides for the fibers to be placed under tension, saturated with thermo-reactive resin, pulled through a series of sized dies to form the fibers into a round bundle while exposed to elevated temperatures such as found in an oven. This process has been used in the making of fishing rods and also adapted for fibreoptic cable members.
SUMMARY OF THE INVENTION
SUMMARY OF THE INVENTION
[0006] In accordance with one aspect of the present invention method of manufacturing a reinforcement for a structural member includes wetting fibers with a resin capable of being cured by at least two different cure treatments. At least partially curing the resin by subjecting the resin to a first cure treatment and at least partially curing the resin by subjecting the resin to a second cure treatment.
[0007] In accordance with another aspect of the present invention a method of manufacturing a reinforced structural member comprising a fiber and resin reinforcement and a structural member is provided. The method includes wetting a plurality of fibers with a curable resin. A plurality of fibers are located adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement. The resin is cured to retain the valleys in the outer side of the reinforcement. The outer side of the reinforcement is adhered to the structural member.
(0008] In accordance with yet another aspect of the present invention an apparatus for manufacturing a reinforcement for a structural member includes a fiber wetting station adapted to contact a plurality of fibers with a resin. A fiber locating mechanism is adapted to locate the plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement and so that a plurality of peaks associated with the fibers are formed. The fiber locating mechanism is further adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement. A resin curing station is adapted to irradiate the outer side of the reinforcement to at least partially cure the resin.
[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0011] Figure 1 is a schematic illustration of an apparatus according to the invention for manufacturing a reinforcement for a structural member;
[0012] Figure 2 is a schematic illustration of an alternative preferred tensioning mechanism;
[0013] Figure 3 is a schematic illustration of an alternative preferred tensioning mechanism;
[0014] Figure 4 is a schematic illustration of an alternative preferred tensioning mechanism;
[0015] Figure 5 is a schematic illustration of an alternative preferred tensioning mechanism;
[0016] Figure 6 is an enlarged fragmentary perspective view of a particularly preferred embodiment of a reinforcement resulting from the method of the present invention; and [0017] Figure 7 is an enlarged cross-sectional view of a preferred reinforced structural member.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0018] The following description of the preferred embodiments) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0019] Referring to Figure 1, a schematic representation of a preferred embodiment of an apparatus of the present invention is illustrated.
A
plurality of creels 10, 11 are provided from which various fibers 12, 13 are supplied. The first creel 10 provides a supply of first fibers 12 and the second creel 11 provides a supply of second fibers 13 made from a different material.
The creels 10, 11 typically include ceramic eyelets 14 through which the fibers 12, 13 pass. In addition to the creels 10, 11 supplying fibers 12, 13, fibers are provided in the form of a thin veil 16 of non-woven fibers from a supply roll 18.
In this case the non-woven veil 16 is made of a plurality of swirled fibers.
Each of the fibers 12, 13, 16 being supplied to the process are preferably tensioned by tensioning device 20. In this embodiment, the tensioning device 20 is associated with the creels 10, 11 and the supply roll 18. The tensioning device is provided by brake wheels 20 which resist the unwinding of the various fibers 12, 13, 16. It is preferred that the tensioning device 20 be adapted to create substantially the same amount of tension in each of the longitudinal 20 fibers 12, 13 of the finished reinforcement.
[0020] Referring to Figures 2-5, various alternative preferred tensioning device 20 embodiments are illustrated. These enable the tensioning of the fibers 12, 13 to be controlled to adjust the tension of the fibers 12.
These devices may also be used to tension the nylon veil 16, although for simplicity they are described herein in terms of fibers 12, 13. Referring to Figure 2, the fibers 12, 13 pass through a pair of non-aligned ceramic eyelets. A bearing roller 50 and weight ball 52 provide tension in the fiber 12, 13 as it is pulled through the eyelets 48. Referring to Figure 3, a biasing spring152 pushes against pressure disks 150 to provide a compressive force on the fiber 12, 13.
Referring to Figure 4, a rubber belt 252 and brake controlled sheave 250 compress the fiber 12, 13 to create tension in the fiber 12, 13. Referring to Figure 5, a pair of ceramic eyelets 48 are moveable on a pivot member 350 to various angles to adjust the amount of tension in the fibers 12, 13.
A
plurality of creels 10, 11 are provided from which various fibers 12, 13 are supplied. The first creel 10 provides a supply of first fibers 12 and the second creel 11 provides a supply of second fibers 13 made from a different material.
The creels 10, 11 typically include ceramic eyelets 14 through which the fibers 12, 13 pass. In addition to the creels 10, 11 supplying fibers 12, 13, fibers are provided in the form of a thin veil 16 of non-woven fibers from a supply roll 18.
In this case the non-woven veil 16 is made of a plurality of swirled fibers.
Each of the fibers 12, 13, 16 being supplied to the process are preferably tensioned by tensioning device 20. In this embodiment, the tensioning device 20 is associated with the creels 10, 11 and the supply roll 18. The tensioning device is provided by brake wheels 20 which resist the unwinding of the various fibers 12, 13, 16. It is preferred that the tensioning device 20 be adapted to create substantially the same amount of tension in each of the longitudinal 20 fibers 12, 13 of the finished reinforcement.
[0020] Referring to Figures 2-5, various alternative preferred tensioning device 20 embodiments are illustrated. These enable the tensioning of the fibers 12, 13 to be controlled to adjust the tension of the fibers 12.
These devices may also be used to tension the nylon veil 16, although for simplicity they are described herein in terms of fibers 12, 13. Referring to Figure 2, the fibers 12, 13 pass through a pair of non-aligned ceramic eyelets. A bearing roller 50 and weight ball 52 provide tension in the fiber 12, 13 as it is pulled through the eyelets 48. Referring to Figure 3, a biasing spring152 pushes against pressure disks 150 to provide a compressive force on the fiber 12, 13.
Referring to Figure 4, a rubber belt 252 and brake controlled sheave 250 compress the fiber 12, 13 to create tension in the fiber 12, 13. Referring to Figure 5, a pair of ceramic eyelets 48 are moveable on a pivot member 350 to various angles to adjust the amount of tension in the fibers 12, 13.
[0021] Returning to Figure 1, the fibers 12, 13 may be rovings, tows, yarn, other fiber bundles or even individual filaments. In addition, fibers 16 are preferably provided to provide strength in the cross direction through the use of a mat, veil, scrim, tape, woven fibers, sewn fibers, and bonded non-wovens.
As described above, this embodiment includes fibers 12 of a first material and fibers 13 of a second material, and a synthetic veil 16. For this specific preferred embodiment, the first fibers 12 are aramid fibers 13, the second fibers are fiberglass and the synthetic veil 16 is made of swirled nylon fibers.
As described above, this embodiment includes fibers 12 of a first material and fibers 13 of a second material, and a synthetic veil 16. For this specific preferred embodiment, the first fibers 12 are aramid fibers 13, the second fibers are fiberglass and the synthetic veil 16 is made of swirled nylon fibers.
[0022] A broad range of fiber materials may be used. Preferred fibers 12, 13, 16 are made of materials selected from fiberglass, aramid, carbon, nylon, polyester, polyethylene, ceramic, steel, metal alloys, and boron.
The first fibers 12 and the cross-directional fibers 16 which are at the outer sides of the reinforcement are preferably made of synthetic fibers; and more preferably, of aramid, nylon, polyester, and polyethylene. The second fibers which are in the interior of the reinforcement are preferably made of mineral fibers; and more preferably, of fiberglass, carbon and ceramic.
The first fibers 12 and the cross-directional fibers 16 which are at the outer sides of the reinforcement are preferably made of synthetic fibers; and more preferably, of aramid, nylon, polyester, and polyethylene. The second fibers which are in the interior of the reinforcement are preferably made of mineral fibers; and more preferably, of fiberglass, carbon and ceramic.
[0023] The tensioned fibers 12, 13, 16 are passed through a resin bath 22 of liquid resin 24 to wet the fibers 12, 13, 16 with the resin 24. The resin 24 is capable of being cured by at least two different cure treatments.
Potential cure treatments include photo-radiation, thermal radiation, electron beam radiation, and radio frequency (e.g., microwave) radiation. More preferably, the resin 24 is a thermosetting resin that is capable of being cured by photo-radiation and thermo-radiation. Examples of preferred resins 24 include polyesters, vinyl esters, epoxy, urethane, and mixtures thereof. More preferred resins 24 are acrylated epoxy and acrylated urethane.
Potential cure treatments include photo-radiation, thermal radiation, electron beam radiation, and radio frequency (e.g., microwave) radiation. More preferably, the resin 24 is a thermosetting resin that is capable of being cured by photo-radiation and thermo-radiation. Examples of preferred resins 24 include polyesters, vinyl esters, epoxy, urethane, and mixtures thereof. More preferred resins 24 are acrylated epoxy and acrylated urethane.
[0024] The wet fibers 12, 13, 16 are then subjected to a forming mechanism 26. The forming mechanism 26 includes doctor blades 28 or other devices to remove excess resin 24 from the fibers 12, 13, 16. The forming mechanism 26 helps in appropriately locating the various fibers 12, 13, 16 relative to each other. In this embodiment, a layer of longitudinally aligned and tensioned first fibers 12 is created adjacent the top outer side. In addition, a central layer is created from longitudinally aligned and tensioned second fibers 13. Lastly, a layer adjacent the bottom outer side is formed from the resin wetted nylon veil 16. The fibers 13, 12, 16 of these three layers are all located adjacent each other with liquid resin material 24 generally filling the space between the fibers 12, 13, 16.
[0025] After passing through the forming mechanism 26 the fibers 12, 13, 16 can have various tendencies to spring away from each other. This is caused by the apparatus design and/or the fiber materials. In addition, the fiber 12, 13, 16 to resin 24 ratio is relatively high. Preferably the fiber 12, 13, 16 to resin 24 ratio is from about 30% to about 70% by volume; more preferably, from about 50% to about 70%; and even more preferably, from about 55% to about 65%.
[0026] Referring to Figure 6, the upper outer side 30 of the combined liquid resin 24 and fiber 12, 13, 16 composite has a series of peaks 32 and valleys 34. The peaks 32 are associated with the outermost fibers 12 which in this embodiment are coated with resin 24. The valleys 34 are created between at least two outermost fibers 12 causing adjacent peaks 32. Thus, the peaks 32 and valleys 34 of the top outer side 30 are elongated and oriented longitudinally along the web. Therefore, this outer side 30 has an undulating profile formed by the longitudinally oriented peaks 32 and valleys 34.
[0027] Returning to Figure 1, the arranged resin coated fibers 12, 13, 16 are next subjected to curing while the top outer side 30 has the peaks 32 and valleys 34. Thus, the undulating surface caused by these peaks 32 and valleys 34 are present in the solid resin 24 and fiber 12, 13, 16 composite or reinforcement 40 which results from curing. The curing is preferably done while the resin is unconfined by a mold, die or film. In this embodiment, curing is accomplished by subjecting the located, tensioned, fibers 12, 13 which have been wetted with liquid resin 24 to ultra-violet (UV) radiation and thermal radiation. Thus, the resin 24 is subjected to two cure treatments. UV lamps 36 provide the source for both the UV radiation and thermal radiation. Since the aramid fibers 12 of this embodiment are not transparent, they create shadows from the UV lamps 36. The additional use of heat provides for efFective curing throughout the resin 24, even in the UV light shadows within the resin 24.
[0028] The heat generated by the UV lamps 36 is sufficient in this embodiment to provide the necessary thermal radiation. Alternatively, additional heat sources are included. The combination of the UV radiation and heat from the lamps 36 is sufficient to fully catalyze the resin. These additional heat sources are preferably selected from infrared heaters, radio frequency (e.g., microwave) heaters, or other devices to provide thermal radiation or convection. Preferably, the resin 24 has a catalyzation that is thermo reactive at a temperature which is at least about 200°F; more preferably at least about 250°F; and even more preferably, at least about 275°F. Such preferred catalyzation temperatures provides a more stable resin system at room temperature or at somewhat elevated temperatures. Since the resin viscosity is dependant on the temperature, this will allow for slightly elevated resin temperature to be used to attain the most suitable viscosity for processing.
[0029] Pairs of wheels 38 operate as pullet clamps to pull the cured composite 40 out of the curing station. Alternative pullet clamps may include caterpillar treads or another clamp and pull source. In this embodiment, the wheels 38 are driven by a drive mechanism (not seen). The wheel pairs 38 provide the force which works in combination with the tensioning device 20 to cause tension on the fibers 12, 13, 16 throughout the curing process. Thus, the fibers 12, 13 of this embodiment are in longitudinal tension while the resin is cured. The pullet clamps 38 feed the cured composite 40 to a roll-up station for storing and subsequent processing plain text. Alternatively, the cured reinforcement is delivered to a cutting station which cuts the reinforcements into desired sizes and shapes.
[0030] Referring to Figure 7, a preferred embodiment of a reinforcement 40 according to the present invention is illustrated. The reinforcement 40 which results from the above is preferably subsequently adhered to a structural member 44. The adhesive 46 flows into the valleys 34 of the reinforcement 40 and bonds to the valleys 34. In addition, the reinforcement 40 is preferably adapted to permit the adhesive 46 to penetrate completely through the overall thickness of the reinforcement 40. Thus, the resin 24 may include pores or cracks in the resin 24 may be encouraged or permitted, for example, by bending the reinforcement 40.
[0031] By bonding to the valleys 34 andlor penetrating completely through the overall thickness of the reinforcement 40 the adhesive 46 creates a particularly strong mechanical bond between the reinforcement 40 and the wood structural member 44. The adhesive 46 may be any type of adhesive suitable for attaching the reinforcement 40 to the structural member 44.
[0032] Many modifications can be made to the above described embodiments. For example, in one alternative the resin may be poured over the already located and tensioned fibers. In another alternative, the fibers may be placed on top of a pool of resin. As another alternative, a veil might be placed on the top side to create the peaks and valleys in association with the swirled fibers of the veil. Thus, the peaks and valleys would not have such a highly elongated shape as that illustrated above. As yet another alternative, the various fibers may be mixed together rather than oriented in layers.
[0033] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
Claims (30)
1. A method of manufacturing a reinforcement for a structural member comprising:
wetting fibers with a resin capable of being cured by at least two different cure treatments at least partially curing the resin by subjecting the resin to a first cure treatment;
at least partially curing the resin by subjecting the resin to a second cure treatment.
wetting fibers with a resin capable of being cured by at least two different cure treatments at least partially curing the resin by subjecting the resin to a first cure treatment;
at least partially curing the resin by subjecting the resin to a second cure treatment.
2. A method of manufacturing a reinforcement according to Claim 1, wherein at least one of the cure treatments is selected from the group consisting of subjecting the resin to light, an electron beam, a radio frequency and heat.
3. A method of manufacturing a reinforcement according to Claim 1, wherein the first cure treatment includes subjecting the resin to UV light and wherein the second cure treatment includes subjecting the resin to heat.
4. A method of manufacturing a reinforcement according to Claim 1, further comprising tensioning the fibers.
5. A method of manufacturing a reinforcement according to Claim 1, further comprising longitudinally aligning the fibers.
6. A method of manufacturing a reinforcement according to Claim 1, further comprising forming a layer from the fibers.
7. A method of manufacturing a reinforcement according to Claim 1, further comprising adding a plurality of fibers adapted to provide cross-direction support for the reinforcement.
8. A method of manufacturing a reinforcement according to Claim 1, wherein curing the resin is done white a side of the reinforcement is unconfined.
9. A method of manufacturing a reinforcement according to Claim 1, further comprising selecting a synthetic fiber as the plurality of fibers.
10. A method of manufacturing a reinforcement according to Claim 1, further comprising selecting a thermosetting plastic as the resin.
11. A method of manufacturing a reinforced structural member comprising a fiber and resin reinforcement and a structural member, the method comprising:
wetting a plurality of fibers with a curable (liquid) resin;
locating a plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement;
curing the resin to retain the valley in the outer side of the reinforcement; and adhering the outer side of the reinforcement to the structural member.
wetting a plurality of fibers with a curable (liquid) resin;
locating a plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement;
curing the resin to retain the valley in the outer side of the reinforcement; and adhering the outer side of the reinforcement to the structural member.
12. A method of manufacturing a reinforced structural member according to Claim 13, further comprising tensioning the fibers.
13. A method of manufacturing a reinforced structural member according to Claim 11, wherein the locating further comprises longitudinally aligning the plurality of fibers.
14. A method of manufacturing a reinforced structural member according to Claim 11, wherein the wetting coats all sides of the fibers with resin.
15. A method of manufacturing a reinforced structural member according to Claim 11, wherein the locating further comprises forming a layer from the fibers.
16. A method of manufacturing a reinforced structural member according to Claim 13, further comprising adding a layer of fibers adapted to provide cross-direction support for the reinforcement.
17. A method of manufacturing a reinforced structural member according to Claim 11, wherein the locating forms the valleys with an elongated shape.
18. A method of manufacturing a reinforced structural member according to Claim 11, wherein the curing further comprises subjecting the resin to at least two cure treatments.
19. A method of manufacturing a reinforced structural member according to Claim 11, wherein the adhering includes the adhesive penetrating completely through a thickness of the fiber and resin reinforcement.
20. A method of manufacturing a reinforced structural member according to Claim 11, wherein curing the resin is done while a side of the reinforcement is unconfined.
21. An apparatus for manufacturing a reinforcement for a structural member comprising:
a fiber wetting station adapted to contact a plurality of fibers with a resin;
a fiber locating mechanism which is adapted to locate the plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement and so that a plurality of peaks associated with the fibers are formed, the fiber locating mechanism being further adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement;
and a resin curing station adapted to irradiate the outer side of the reinforcement to at least partially cure the resin.
a fiber wetting station adapted to contact a plurality of fibers with a resin;
a fiber locating mechanism which is adapted to locate the plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement and so that a plurality of peaks associated with the fibers are formed, the fiber locating mechanism being further adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement;
and a resin curing station adapted to irradiate the outer side of the reinforcement to at least partially cure the resin.
22. An apparatus for manufacturing a reinforcement according to Claim 21, wherein the fiber locating mechanism is adapted to form the peaks and the valleys with an elongated shape.
23. An apparatus for manufacturing a reinforcement according to Claim 21, wherein the wetting station is further adapted to coat all sides of the plurality of fibers with resin.
24. An apparatus for manufacturing a reinforcement according to Claim 21, further comprising an additional fiber locating mechanism adapted to locate a second plurality of fibers in contact with the resin so the second plurality of fibers provide cross-direction support for the reinforcement.
25. An apparatus for manufacturing a reinforcement according to Claim 21, wherein the resin curing station has at least two of a light source, an electron beam source, a radio frequency source and a heat source.
26 An apparatus for manufacturing a reinforcement according to Claim 25, wherein the at least two sources are provided by a single device.
27. An apparatus for manufacturing a reinforcement according to Claim 21, further comprising a tensioning mechanism adapted to place fibers under tension during curing.
28. An apparatus for manufacturing a reinforcement according to Claim 27, wherein the tensioning mechanism has ceramic eyelets oriented at an angle to a path of a fiber passing through the ceramic eyelet.
29. An apparatus for manufacturing a reinforcement according to Claim 27, wherein the tensioning mechanism has an unwind brake associated with a spool adapted to supply fibers.
30. An apparatus for manufacturing a reinforcement according to Claim 27, wherein the tensioning mechanism is adapted to provide a compressive force against a fiber.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/350,465 | 2003-01-24 | ||
| US10/350,465 US6893524B2 (en) | 2003-01-24 | 2003-01-24 | Method and apparatus for manufacturing a reinforcement |
| PCT/US2004/001493 WO2004067662A2 (en) | 2003-01-24 | 2004-01-21 | Method and apparatus for manufacturing a reinforcement |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2514178A1 true CA2514178A1 (en) | 2004-08-12 |
Family
ID=32735565
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002514178A Abandoned CA2514178A1 (en) | 2003-01-24 | 2004-01-21 | Method and apparatus for manufacturing a reinforcement |
Country Status (4)
| Country | Link |
|---|---|
| US (2) | US6893524B2 (en) |
| CA (1) | CA2514178A1 (en) |
| MX (1) | MXPA05007869A (en) |
| WO (1) | WO2004067662A2 (en) |
Families Citing this family (21)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7093638B2 (en) * | 2003-04-21 | 2006-08-22 | Lignum Vitae Limited | Apparatus and method for manufacture and use of composite fiber components |
| US7875675B2 (en) | 2005-11-23 | 2011-01-25 | Milgard Manufacturing Incorporated | Resin for composite structures |
| US8597016B2 (en) | 2005-11-23 | 2013-12-03 | Milgard Manufacturing Incorporated | System for producing pultruded components |
| US8101107B2 (en) * | 2005-11-23 | 2012-01-24 | Milgard Manufacturing Incorporated | Method for producing pultruded components |
| US7901762B2 (en) | 2005-11-23 | 2011-03-08 | Milgard Manufacturing Incorporated | Pultruded component |
| US8273450B2 (en) * | 2008-08-08 | 2012-09-25 | Green David E | Thermoset polyurethane matrix fiber reinforced composite |
| US8123515B2 (en) * | 2008-10-02 | 2012-02-28 | Robert Frank Schleelein | System and method for producing composite materials with variable shapes |
| CN102574302B (en) * | 2009-05-04 | 2015-04-15 | 费萨尔.H.-J.纳普 | Method and device for producing a thread made of a plurality of individual filaments, and monofilament thread produced in this manner |
| US8567734B2 (en) * | 2009-09-14 | 2013-10-29 | Underground Devices, Inc | Cable support system |
| DE102010009354A1 (en) * | 2010-02-25 | 2011-08-25 | Magna Exteriors & Interiors (Bohemia) S.R.O. | structural component |
| US11485968B2 (en) | 2012-02-13 | 2022-11-01 | Neumodx Molecular, Inc. | Microfluidic cartridge for processing and detecting nucleic acids |
| US9604213B2 (en) | 2012-02-13 | 2017-03-28 | Neumodx Molecular, Inc. | System and method for processing and detecting nucleic acids |
| US11648561B2 (en) | 2012-02-13 | 2023-05-16 | Neumodx Molecular, Inc. | System and method for processing and detecting nucleic acids |
| CN114134029A (en) | 2012-02-13 | 2022-03-04 | 纽莫德克斯莫勒库拉尔公司 | Microfluidic cartridge for processing and detecting nucleic acids |
| US9637775B2 (en) | 2012-02-13 | 2017-05-02 | Neumodx Molecular, Inc. | System and method for processing biological samples |
| US20140120544A1 (en) | 2012-10-25 | 2014-05-01 | Neumodx Molecular, Inc. | Method and materials for isolation of nucleic acid materials |
| DE102015209662A1 (en) * | 2015-05-27 | 2016-12-01 | Voith Patent Gmbh | Process for producing laminates of fiber-reinforced plastic |
| EP3241670B1 (en) * | 2016-04-01 | 2022-09-14 | Firestone Industrial Products Company, LLC | Systems and methods of manufacturing flexible spring members for gas spring assemblies |
| US10858275B2 (en) | 2016-06-16 | 2020-12-08 | Usb I, Llc | Apparatus and process for producing fiber from igneous rock |
| US10369754B2 (en) | 2017-02-03 | 2019-08-06 | Oleksandr Biland | Composite fibers and method of producing fibers |
| CN112427272A (en) * | 2020-10-21 | 2021-03-02 | 嘉兴意飞光电科技有限公司 | Novel duplex position UV solidification machine |
Family Cites Families (60)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2536183A (en) * | 1944-03-20 | 1951-01-02 | Union Carbide & Carbon Corp | Preparation of surfaces for adhesion |
| US3413188A (en) * | 1963-06-14 | 1968-11-26 | Westinghouse Electric Corp | Glass fiber-wood laminates and methods of producing such laminates |
| US3895896A (en) * | 1972-11-03 | 1975-07-22 | Pultrusions Corp | Apparatus for pultruding hollow objects |
| US3890077A (en) * | 1973-01-05 | 1975-06-17 | John A Holman | Apparatus for manufacturing artificial boards and shapes |
| GB1550363A (en) * | 1975-05-08 | 1979-08-15 | Ici Ltd | Envelope |
| US4066805A (en) * | 1976-02-23 | 1978-01-03 | Armstrong Cork Company | Method of achieving a two-toned fiberboard product |
| US4242406A (en) * | 1979-04-30 | 1980-12-30 | Ppg Industries, Inc. | Fiber reinforced composite structural laminate composed of two layers tied to one another by embedded fibers bridging both layers |
| US4312162A (en) * | 1979-08-15 | 1982-01-26 | Jonas Medney | Reinforced pole |
| US4474920A (en) * | 1981-04-08 | 1984-10-02 | The Celotex Corporation | Embossable coating |
| JPS58142956A (en) * | 1982-02-18 | 1983-08-25 | Takeda Chem Ind Ltd | Primer for bonding polyester resin |
| US5130184A (en) * | 1984-04-25 | 1992-07-14 | Pyrotite Corporation | Fire barrier coating and fire barrier plywood |
| NO162124C (en) * | 1984-06-22 | 1989-11-08 | Arne Engebretsen | TREATED BENCH OF WOODWOOD. |
| US4615163A (en) * | 1984-10-04 | 1986-10-07 | Curtis Albert B | Reinforced lumber |
| US4892764A (en) * | 1985-11-26 | 1990-01-09 | Loctite Corporation | Fiber/resin composites, and method of making the same |
| US4740409A (en) | 1987-03-31 | 1988-04-26 | Lefkowitz Leonard R | Nonwoven fabric and method of manufacture |
| JPS641526A (en) * | 1987-04-27 | 1989-01-05 | Toyo Cloth Kk | Molding of composite material by means of ultra-violet ray curing |
| US5000808A (en) * | 1988-05-13 | 1991-03-19 | Deviney George L | Application of continuous strand material to planar substrates |
| US5026593A (en) * | 1988-08-25 | 1991-06-25 | Elk River Enterprises, Inc. | Reinforced laminated beam |
| US5061545A (en) * | 1988-11-28 | 1991-10-29 | Allied-Signal Inc. | Fiber/polymer composite with nonuniformly distributed polymer matrix |
| US5198281A (en) * | 1989-04-17 | 1993-03-30 | Georgia Tech Research Corporation | Non-woven flexible multiply towpreg fabric |
| US5153058A (en) * | 1989-05-11 | 1992-10-06 | General Electric Company | Fiber reinforced thermoplastic composites as fire/heat barriers for combustible substrates |
| US4957801A (en) * | 1989-05-17 | 1990-09-18 | American Cyanamid Company | Advance composites with thermoplastic particles at the interface between layers |
| US5006390A (en) * | 1989-06-19 | 1991-04-09 | Allied-Signal | Rigid polyethylene reinforced composites having improved short beam shear strength |
| US5573813A (en) * | 1990-03-02 | 1996-11-12 | Hexcel Corporation | Method and apparatus for impregnating fibers with highly viscous materials and article made therewith |
| US5135793A (en) * | 1990-05-24 | 1992-08-04 | The Standard Oil Company | Fiberglass reinforced polyester laminated hardboard panels |
| US5213742A (en) * | 1990-09-11 | 1993-05-25 | Vitaphore Corporation | Method of producing pores of controlled geometry on a thermoplastic polymer |
| JP2931068B2 (en) | 1990-10-11 | 1999-08-09 | 住友林業株式会社 | Reinforced wood |
| WO1993003087A1 (en) * | 1991-08-09 | 1993-02-18 | Kabushiki Kaisha Kobeseikosho | Carbon fiber prepreg and carbon fiber reinforced resin |
| US5286320A (en) * | 1991-11-18 | 1994-02-15 | Owens-Corning Fiberglas Technology Inc. | Method for making a pultruded panel |
| ATE170798T1 (en) * | 1991-11-28 | 1998-09-15 | Solutia Europ Nv Sa | NYLON PULTRUSION PROCESS |
| US5264060A (en) * | 1992-01-22 | 1993-11-23 | Aluminum Company Of America | Method for pultruding fiber-reinforced thermoplastic stock |
| KR930019736A (en) * | 1992-03-30 | 1993-10-18 | 마에다 카쯔노수케 | Prepreg and Fiber Reinforced Composites |
| US5736220A (en) * | 1993-03-24 | 1998-04-07 | Tingley; Daniel A. | Surface treated synthetic reinforcement for structural wood members |
| US5648138A (en) * | 1993-03-24 | 1997-07-15 | Tingley; Daniel A. | Reinforced wood structural member |
| US5547729A (en) * | 1993-03-24 | 1996-08-20 | Tingley; Daniel A. | Glue-laminated wood structural member with synthetic fiber reinforcement |
| US6173550B1 (en) * | 1993-03-24 | 2001-01-16 | Daniel A. Tingley | Wood I-beam conditioned reinforcement panel |
| US5974760A (en) * | 1993-03-24 | 1999-11-02 | Tingley; Daniel A. | Wood I-beam with synthetic fiber reinforcement |
| US5456781A (en) * | 1993-03-24 | 1995-10-10 | Tingley; Daniel A. | Method of manufacturing glue-laminated wood structural member with synthetic fiber reinforcement |
| US5362545A (en) * | 1993-03-24 | 1994-11-08 | Tingley Daniel A | Aligned fiber reinforcement panel for structural wood members |
| US5641553A (en) * | 1993-03-24 | 1997-06-24 | Tingley; Daniel A. | Cellulose surface material adhered to a reinforcement panel for structural wood members |
| US5565257A (en) * | 1993-03-24 | 1996-10-15 | Tingley; Daniel A. | Method of manufacturing wood structural member with synthetic fiber reinforcement |
| US5498460A (en) * | 1993-03-24 | 1996-03-12 | Tingley; Daniel A. | Surface treated synthetic reinforcement for structural wood members |
| US5721036A (en) * | 1993-03-24 | 1998-02-24 | Tingley; Daniel A. | Aligned fiber reinforcement panel and method for making the same for use in structural wood members |
| DE4317649A1 (en) * | 1993-05-27 | 1994-12-01 | Hoechst Ag | Glass fiber reinforced composite material and method for its production |
| US5424388A (en) * | 1993-06-24 | 1995-06-13 | Industrial Technology Research Institute | Pultrusion process for long fiber-reinforced nylon composites |
| US5744228A (en) * | 1994-03-04 | 1998-04-28 | Tingley; Daniel A. | Use of synthetic fibers in a glueline to increase resistance to sag in wood and wood composite structures |
| US5609806A (en) * | 1994-06-28 | 1997-03-11 | Reichhold Chemicals, Inc. | Method of making prepreg |
| US5441792A (en) * | 1994-08-17 | 1995-08-15 | Armstrong World Industries, Inc. | Two layered composite embossed board |
| US5556496A (en) * | 1995-01-10 | 1996-09-17 | Sumerak; Joseph E. | Pultrusion method for making variable cross-section thermoset articles |
| GB9501605D0 (en) * | 1995-01-27 | 1995-03-15 | Kobe Steel Europ Ltd | Radiation-curable compositions |
| US5783013A (en) * | 1995-06-07 | 1998-07-21 | Owens-Corning Fiberglas Technology Inc. | Method for performing resin injected pultrusion employing multiple resins |
| US5647171A (en) * | 1995-12-26 | 1997-07-15 | General Motors Corporation | Hard-top vehicle window regulator system |
| US5891550A (en) * | 1996-02-05 | 1999-04-06 | Tingley; Daniel A. | Structural member with increased shear resistance |
| US5747151A (en) * | 1996-03-12 | 1998-05-05 | Tingley; Daniel A. | Glue-laminated wood structural member with sacrificial edges |
| US6045876A (en) * | 1996-04-10 | 2000-04-04 | Fellers; John F. | System and method for impregnating a continuous fiber strand with a polymer melt |
| US6037049A (en) * | 1996-05-09 | 2000-03-14 | Tingley; Daniel A. | Reinforcement panel sheet to be adhered to a wood structural member |
| US5948472A (en) * | 1996-09-10 | 1999-09-07 | Lawrie Technology, Inc. | Method for making a pultruded product |
| US5936368A (en) * | 1998-04-08 | 1999-08-10 | Reliance Electric Industrial Company | Non-linear proportional/integral feedback controller |
| US20010002609A1 (en) * | 1998-08-17 | 2001-06-07 | Habib Dagher | Method of manufacturing reinforced wood composites |
| US6279849B1 (en) * | 1999-11-19 | 2001-08-28 | Mccoy-Ellison, Inc. | Magnetic chuck for unwinding of wire from a spool |
-
2003
- 2003-01-24 US US10/350,465 patent/US6893524B2/en not_active Expired - Lifetime
-
2004
- 2004-01-21 WO PCT/US2004/001493 patent/WO2004067662A2/en active Application Filing
- 2004-01-21 MX MXPA05007869A patent/MXPA05007869A/en active IP Right Grant
- 2004-01-21 CA CA002514178A patent/CA2514178A1/en not_active Abandoned
-
2005
- 2005-05-09 US US11/124,834 patent/US20050205199A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20050205199A1 (en) | 2005-09-22 |
| US6893524B2 (en) | 2005-05-17 |
| US20040144478A1 (en) | 2004-07-29 |
| WO2004067662A2 (en) | 2004-08-12 |
| MXPA05007869A (en) | 2005-11-16 |
| WO2004067662A3 (en) | 2005-02-24 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US20050205199A1 (en) | Method and apparatus for manufacturing a reinforcement | |
| US8123887B2 (en) | Continuously formed fiber reinforced composite strength member | |
| CA2156417C (en) | Aligned fiber reinforcement panel for wood members | |
| DK3019330T3 (en) | PROCEDURE FOR MANUFACTURING A REINFORCEMENT BAR | |
| US5456781A (en) | Method of manufacturing glue-laminated wood structural member with synthetic fiber reinforcement | |
| EP2301045B1 (en) | Pultrusion process for the manufacture of fiber reinforced composites | |
| US20190118495A1 (en) | Flat fiber-reinforced plastic strand, flat fiber-reinforced plastic strand sheet, and method of manufacturing the same | |
| US5721036A (en) | Aligned fiber reinforcement panel and method for making the same for use in structural wood members | |
| US20040238106A1 (en) | Prepreg forming apparatus | |
| US6174483B1 (en) | Laminate configuration for reinforcing glulam beams | |
| US7875337B2 (en) | Fiber and resin composite reinforcement | |
| JP4252778B2 (en) | Method for continuously producing molded body and molded body | |
| GB2159845A (en) | Improvements in and relating to fibre reinforcing tape | |
| WO2012130732A1 (en) | Method for producing a prepreg and an organic sheet that can be obtained therefrom | |
| DE102011076546A1 (en) | Producing prepreg, useful for producing organic sheet or hybrid component, comprises providing textile material, applying reactive thermoplastic precursor and reactive duroplastic precursor on textile material, impregnating textile material | |
| JP3308965B2 (en) | Prepreg | |
| JPH03222734A (en) | Unidirectionally arranged reinforcing fiber sheet and manufacture thereof | |
| JPH04316810A (en) | Method and equipment to assemble sheet of composite material | |
| JPH04163130A (en) | Preparation of fiber reinforced resin molded body |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |