Apparatus and method for producing elongated reinforced plastic articles

• US 3,873,399 A
• Filed: 05/09/1973
• Issued: 03/25/1975
• Est. Priority Date: 05/09/1973
• Status: Expired due to Term

• Current Assignee: Ethridge E. Hardesty, Harald E. Karlson, William Brandt Goldsworthy
• Original Assignee: Ethridge E. Hardesty, Harald E. Karlson, William Brandt Goldsworthy
• Inventors: Hardesty, Ethridge E., Karlson, Harald E., Goldsworthy, William Brandt
• Primary Examiner(s): Fritsch, Daniel J.
• Application Number:
  US05/358,665
• Time in Patent Office: 685 Days
• Field of Search: 156/180,245,441,500 425/383,385,392,394,395 264/281,310
• US Class Current: 156/441
• CPC Class Codes: B29C 70/525 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 70/527 Pulling means

Abstract

An apparatus and method for pultruding a continuously formed elongated non-linear composite article comprised of filament containing reinforcing material and in impregnatable curable matrix. In one embodiment of the apparatus and method, resin impregnated reinforcing material is pulled through a preheating zone and then introduced with respect to a pair of die frames. These die frames are operatively mounted for rotational movement about a main shaft, and respectively carry first and second arcuately shaped die sections which are movable past and cooperate with a fixed die section to form an arcuately shaped die cavity therebetween. The resin impregnated reinforcing material is moved with the first and second die sections during rotation thereof into and through the die cavity where the shape of the die cavity is imparted to the impregnated reinforcing material. A final curing mechanism is associated with the rotatable die frames to cure the matrix in the reinforcing material as it moves through the die cavity to thereby produce a rigid nonlinear pultruded article. The first and second die frames are initially connected to form a continuous die cavity with the fixed die section. When the first die frame completely passes the fixed die section, it is disconnected from the second die frame and swung around into a position where it is located immediately rearwardly of the first die section in the direction of movement of the reinforcing material. When the second die section completely passes the fixed die section it is likewise swung around to a position immediately rearwardly of the first die section, and these movable die sections will be continuously moved in like manner to form a continuous process. In a second embodiment of the apparatus and method, resin impregnated reinforcing material is pulled through a preheating zone and then introduced into an initial shaping and forming die. The material is then introduced into an externally heated consolidation and curing die having a die cavity which is curved over its length in the direction of movement of the material. A final cure is imparted to the resin in the reinforcing material in this consolidation and curing die. A pulling mechanism is used to pull the impregnated reinforcing material through the preheating zone and the aforesaid dies.

Claims

1. Apparatus for pultruding a continuously formed non-linear composite article comprised of filament containing reinforcing material and an impregnating curable matrix, said apparatus comprising:

a. pre-heating means operatively located to receive a reinforcing material impregnated with a curable matrix, b. a forming and shaping die comprising a first and second cooperating die sections which are arcuately curved over their length forming a die cavity therebetween, said die cavity being operatively located in relation to said pre-heating means to receive the impregnated and pre-heated reinforcing material, c. said die cavity being defined by said first and second die sections and curved over the greater portion of its length in the direction of movement of the reinforcing material, d. and curing means operatively located with respect to said forming and shaping die to finally cure the curable matrix impregnated into said reinforcing material, to thereby form a rigid pultruded composite article, e. and pulling means for carrying said reinforcing material impregnated with said curable matrix through said pre-heating means and the die cavity of said forming and shaping die.

2. The apparatus of claim 1 further characterized in that said apparatus comprises an additional die section located upstream of said forming and shaping die in the direction of movement of said impregnated reinforcing material, said additional die also cooperating in the forming of a die cavity to receive the curable matrix imprEgnated reinforcing material to shape and form said impregnated reinforcing material.

3. The apparatus of claim 2 further characterized in that one die section of said forming and shaping die is fixed with respect to the movement of said reinforcing material.

4. The apparatus of claim 1 further characterized in that said forming and shaping die comprises said second die section which is fixed and said first die section which moves relative to said second die section, and an additional die section movable with respect to said second die section and also being located to also form a die cavity therebetween to receive the curable matrix impregnated reinforcing material.

5. Apparatus for pultruding a continuously formed non-linear composite article comprised of filament containing reinforcing material and an impregnating curable matrix, said apparatus comprising:

a. base means, b. a first die section operatively mounted on said base means and being sized to receive a curable matrix impregnated reinforcing material, c. a cooperating second die section operatively disposed in relation to said first die section and being located to form a die cavity therebetween to receive the curable matrix impregnated reinforcing material, d. said first and second die sections being curved over the greater portion of their lengths in the direction of movement of said matrix impregnated reinforcing material so that said die cavity is curved over the greater portion of its length, e. means for moving one of said first die section and said cooperating die section relative to one another and carrying said curable matrix impregnated reinforcing material therewith through said die cavity during said relative movement, f. and curing means operatively located with respect to at least one of said first die section and second cooperating die section to cure the curable matrix impregnated into said reinforcing material, to thereby form a rigid pultruded composite article.

6. The apparatus of claim 5 further characterized in that said first die section is movable with respect to said second cooperating die section and that said second cooperating die section is fixedly located to form said die cavity when said first die section moves with respect thereto.

7. The apparatus of claim 5 further characterized in that said curing means is carried by at least one of said first die section or said second cooperating die section for curing the matrix impregnated into said reinforcing material as said impregnated reinforcing material passes the stationary one of said first die section or cooperating second die section.

8. The apparatus of claim 6 further characterized in that said first die section and said second cooperating die section are curved in the direction of movement of the matrix impregnated reinforcing material, said second die section having a cavity formed therein to function as a female die and said first die section having a plug thereon to function as a male die and which cavity and plug are curved so as form a curved pultruded article.

9. The apparatus of claim 6 further characterized in that said apparatus comprises an additional die section which is mounted on said base means and moves relative to said second cooperating die section and said first die section, said additional die section also moving in relation to said second cooperating die section and being curved over the greater portion of its length and located to also form a die cavity therebetween to receive the curable matrix impregnated reinforcing material.

10. The apparatus of claim 9 further characterized in that said first and additional die sections move about a common axis on said base means in circular path.

11. The apparatus of claim 5 further characterized in that said reinforcing material comprises filament containing strands.

12. The apparatus of claim 5 further characterized in that said reinforcing material comprises any member selected from the class consisting of fiLament containing fabric material, filament containing web material, filament containing mat material, filament containing strands, filament containing tapes, and combinations of the foregoing.

13. The apparatus of claim 5 further characterized in that said reinforcing material comprises a combination of filament containing strands and filament mat material.

14. An apparatus for continuously producing a non-linear composite article comprised of filament reinforcing material and an impregnating curable matrix, said apparatus comprising:

a. means for introducing said matrix impregnated reinforcing material into a pre-heating zone to preheat the matrix sufficiently to augment a final cure thereof, b. a die cavity formed by a shaping and forming die operatively located with respect to said pre-heating zone and located to receive the matrix impregnated reinforcing material, and which die cavity is curved over its length in the direction of movement of said material, c. means for introducing additional heat into said matrix impregnated reinforcing material to finally cure the matrix during the movement of said matrix impregnated reinforcing material in said die cavity to thereby form a non-linear composite article, d. and means for moving said matrix impregnated reinforcing material through said pre-heating zone and said die cavity in a non-linear path in the direction of movement of said matrix impregnated reinforcing material.

15. The apparatus for producing a non-linear composite article of claim 14 further characterized in that said shaping and forming die is fixed and said reinforcing material is pulled through the fixed die cavity.

16. The apparatus for producing a non-linear composite article of claim 14 further characterized in that said shaping and forming die includes a movable die forming element and a stationary die forming element and the apparatus comprises means for moving the matrix impregnated reinforcing material with said movable die forming element.

17. An apparatus for continuously producing a non-linear composite article comprised of filament reinforcing material and an impregnating curable matrix, said apparatus comprising:

a. means for contacting said reinforcing material with said curable matrix and impregnating said matrix into said reinforcing material, b. a movable die forming element and a stationary die forming element cooperatively located with respect to said movable die forming element and arranged to form an arcuately shaped die cavity located to receive the matrix impregnated reinforcing material, c. pulling means for moving said matrix impregnated reinforcing material with said movable die forming element in a non-linear path in the direction of movement of said matrix impregnated reinforcing material, d. means for introducing heat into said matrix impregnated reinforcing material to thereby form a nonlinear composite article, e. and said pulling means moving said composite article thus formed from said die cavity.

18. The apparatus for producing a non-linear composite article of claim 17 further characterized in that said movable and stationary die-forming elements are arcuately shaped so that said matrix impregnated reinforcing material is moved in an arcuate path with said movable die forming element.

19. The apparatus of producing a non-linear composite article of claim 17 further characterized in that the apparatus comprises:

a. an extension of said die cavity formed by said stationary die forming element and an additional movable die forming element cooperatively located with respect to said stationary die forming element to receive subsequent portions of the matrix impregnated reinforcing material, b. means for introducing heat into the subsequent portions of said matrix impregnated reinforcing material to cure said subsequent portions during movement thereof to form a non-linear composite extended portion on said composite article being formed, c. and said pulling means moving said composite extended portion from said die cavity.

20. The apparatus for producing a non-linear composite article of claim 19 further characterized in that power means moves said first named movable die forming element to a position where it is located behind said additional die forming element in the direction of movement thereof to move with still additional subsequent portions of said matrix impregnated reinforcing material with respect to said stationary die forming element.

21. Apparatus for producing reinforced plastic stock material comprised of a filament containing reinforcing material impregnated with a curable matrix, said apparatus comprising:

a. base means, b. a first movable die section arcuately shaped over at least the greater portion of its length and being also movable in an arcuate path about an axis on said base means, an additional movable die section arcuately shaped over at least the greater portion of its length and being also movable in an arcuate path about said axis, d. an arcuately shaped stationary die section locatable in a path to form a die cavity with said first and additional movable die sections, e. means for moving said first and additional die sections relative to said stationary die section and also moving the matrix impregnated reinforcing material therewith and through said die cavity, f. and curing means operatively associated with said first and additional die sections and curing the matrix during movement through said die cavity, to form a rigid reinforced plastic stock material.

22. The apparatus of claim 21 further characterized in that said first and additional movable die sections move in a common relatively horizontal plane relative to said stationary die element.

23. The apparatus of claim 21 further characterized in that said apparatus comprises motive means for moving said first and additional die sections simultaneously in a common plane relative to said stationary die element, and means to permit said first and additional die sections to be moved in said common plane individually with respect to each other.

24. Apparatus for pultruding a continuously formed non-linear composite article comprised of filament containing reinforcing material and an impregnating durable matrix, said apparatus comprising:

a. receiving means operatively located to receive a reinforcing material impregnated with a curable matrix, b. a forming and shaping die comprising a first and second cooperating die sections which are arcuately curved over their length forming a die cavity therebetween, said die cavity being operatively located in relation to said receiving means to receive the impregnated reinforcing material, c. said die cavity being defined by said first and second die sections and curved over the greater portion of its length in the direction of movement of the reinforcing material, d. and curing means operatively located with respect to said forming and shaping die to finally cure the curable matrix impregnated into said reinforcing material, to thereby form a rigid pultruded composite article, e. and pulling means for carrying said reinforcing material impregnated with said curable matrix through said receiving means and the die cavity of said forming and shaping die.

25. The apparatus of claim 24 further characterized in that said apparatus comprises an additional die section located upstream of said forming and shaping die in the direction of movement of said impregnated reinforcing material, said additional die also cooperating in the forming of a die cavity to receive the curable matrix impregnated reinforcing material to shape and form said impregnated reinforcing material.

26. The apparatus of claim 24 further characterized in that one die section of said forming and shaping die is fixed with respect to the movement of said reinforcing material.

27. The apparatus of claim 24 further characterized in that said forming and shaping die comprises said second die section which is fixed and said first die section which moves relative to said second die section, and an additional die section which moves with respect to said second die section and also being located to also form a die cavity therebetween to receive the curable matrix impregnated reinforcing material.

28. The apparatus of claim 24 further characterized in that said filament containing reinforcing material is comprised of a plurality of layers and in which at least one of the layers is formed of a different filament containing material than another layer thereof.