Pultruded component

• US 7,901,762 B2
• Filed: 11/23/2005
• Issued: 03/08/2011
• Est. Priority Date: 11/23/2005
• Status: Expired due to Fees

• Current Assignee: Milgard Manufacturing Incorporated (MI Windows & Doors LLC)
• Original Assignee: Milgard Manufacturing Incorporated (MI Windows & Doors LLC)
• Inventors: Huang, Icheng, Coffee, Harry D., Kharchenko, Semen, Brown, Randall Jay
• Primary Examiner(s): Sample; David R
• Assistant Examiner(s): Gugliotta; Nicole T
• Application Number:
  US11/287,142
• Publication Number:
  US 20070116941A1
• Time in Patent Office: 1,931 Days
• Field of Search: None
• US Class Current: 428/298.1
• CPC Class Codes: C08G 18/4812 Mixtures of polyetherdiols with polyetherpolyols having at least three hydroxy groups
• CPC Class Codes: C08K 7/14 Glass
• CPC Class Codes: C08L 75/04 Polyurethanes
• CPC Class Codes: Y10T 428/249942 Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/249945 Carbon or carbonaceous fiber
• CPC Class Codes: Y10T 428/249946 Glass fiber
• CPC Class Codes: Y10T 428/249947 Polymeric fiber

Abstract

A pultruded composite component includes a matrix material comprising a thermosetting polyurethane resin, and fibers provided within the resin matrix. All of the fibers within the resin matrix are oriented in substantially a single direction and the matrix material has an elongation-to-failure that exceeds that of the fibers.

Claims

1. A pultruded composite component comprising:

a matrix material comprising a thermosetting polyurethane resin, the polyurethane resin comprising an isocyanate component and a blend of three polyether polyols, the blend comprising between approximately 20% and 50% of a first polyol having a molecular weight of between approximately 600 and 800, between approximately 20% and 40% of a second polyol having a molecular weight of between approximately 200 and 300, and between approximately 20% and 50% of a third polyol having a molecular weight of between approximately 100 and 300; and

fibers provided within the resin matrix;

wherein all of the fibers within the resin matrix are oriented in substantially a single direction and the matrix material has an elongation-to-failure that exceeds that of the fibers.

2. The pultruded composite component of claim 1, wherein the isocyanate component comprises a material selected from the group consisting of diphenylmethane diisocyanate, a polymeric isomer of diphenylmethane diisocyanate, and combinations thereof.

3. The pultruded composite component of claim 1, wherein the first polyol has an OH index of between approximately 200 and 300 mgOH/g, the second polyol has an OH index of between approximately 500 and 700 mgOH/g, and the third polyol has an OH index of between approximately 800 and 1200 mgOH/g.

4. The pultruded composite component of claim 1, wherein the first polyol has an OH index of between approximately 230 and 250 mgOH/g, the second polyol has an OH index of between approximately 600 and 700 mgOH/g, and the third polyol has an OH index of between approximately 900 and 1100 mgOH/g.

5. The pultruded composite component of claim 1, wherein the first polyol has a viscosity of less than approximately 500 cps, the second polyol has a viscosity of less than approximately 1000 cps, and the third polyol has a viscosity of less than approximately 2000 cps.

6. The pultruded composite component of claim 1, wherein the first polyol has a viscosity of less than approximately 400 cps, the second polyol has a viscosity of less than approximately 900 cps, and the third polyol has a viscosity of less than approximately 1500 cps.

7. The pultruded composite component of claim 1, wherein the first polyol has a molecular weight of between approximately 650 and 750, the second polyol has a molecular weight of between approximately 225 and 275, and the third polyol has a molecular weight of between approximately 125 and 200.

8. The pultruded composite component of claim 1, wherein the blend has an OH index between approximately 350 and 750 mgOH/g.

9. The pultruded composite component of claim 1, wherein the blend has an OH index between approximately 625 and 725 mgOH/g.

10. The pultruded composite component of claim 1, wherein the first polyol has an OH index between approximately 200 and 300 mgOH/g.

11. The pultruded composite component of claim 1, wherein the second polyol has an OH index between approximately 500 and 700 mgOH/g.

12. The pultruded composite component of claim 1, wherein the third polyol has an OH index between approximately 800 and 1200 mgOH/g.

13. The pultruded composite component of claim 1, wherein the first polyol has an OH index of between approximately 200 and 300 mgOH/g and a viscosity of less than approximately 500 cps, the second polyol has an OH index of between approximately 500 and 700 mgOH/g and a viscosity of less than approximately 1000 cps, and the third polyol has an OH index of between approximately 800 and 1200 mgOH/g and a viscosity of less than approximately 2000 cps.

14. The pultruded composite component of claim 1, wherein the blend comprises between approximately 25% and 35% of the first polyol, between approximately 25% and 35% of the second polyol, and between approximately 30% and 45% of the third polyol.

15. The pultruded composite component of claim 1, wherein the ratio of the isocyanate component to the blend is between approximately 80% and 115% of stoichiometric and the matrix material further comprises a mold release material and a filler material.

16. The pultruded composite component of claim 15, wherein the mold release material is provided in an amount of between approximately 0.5% and 5% of the total mass of the resin precursor composition.

17. The pultruded composite component of claim 15, wherein the filler comprises at least one material selected from the group consisting of caolin clay, calcium carbonate, and combinations thereof.

18. The pultruded composite component of claim 1, wherein the matrix material has an elastic modulus of between approximately 350,000 and 500,000 psi after curing.

19. The pultruded composite component of claim 1, wherein the matrix material has an elongation-to-failure of between approximately 6% and 15% after curing.

20. The pultruded composite component of claim 1, wherein the fibers are selected from the group consisting of glass fibers, polymeric fibers, carbon fibers, and combinations thereof.

21. The pultruded composite component of claim 1, wherein the fibers are provided in the matrix material as fiber tows.

22. The pultruded composite component of claim 1, wherein the pultruded composite component has a longitudinal axis and a transverse axis, and the fibers are oriented substantially parallel to the longitudinal axis.

23. The pultruded composite component of claim 1, wherein the thermosetting polyurethane resin further comprises a polymeric additive configured to counteract shrinkage of the resin composition during polymerization.

24. The pultruded composite component of claim 1, wherein the pultruded composite component is a lineal for a window or door.

25. A lineal for use in a window or door comprising:

a thermosetting polyurethane resin; and

a reinforcement material for the lineal provided within the polyurethane resin, the reinforcement material consisting of fiber tows oriented substantially parallel to each other;

wherein the thermosetting polyurethane resin has an elongation-to-failure that is substantially equal to or greater than an elongation-to-failure of the reinforcement material and comprises an isocyanate material and a polyol component, the polyol component comprising;

(a) a first polyether polyol having a functionality of three and a molecular weight of between approximately 600 and 800 and an OH index of between approximately 200 and 300 mgOH/g;

(b) a second polyether polyol having a functionality of three and a molecular weight of between approximately 200 and 300 and an OH index of between approximately 500 and 700 mgOH/g; and

(c) a third polyether polyol having a functionality of three and a molecular weight of between approximately 100 and 300 and an OH index of between approximately 800 and 1200 mgOH/g;

wherein the polyol component comprises between approximately 20% and 50% of the first polyether polyol, between approximately 20 and 40% of the second polyether polyol, and between approximately 20 and 50% of the third polyether polyol.

26. The lineal of claim 25, wherein the isocyanate material comprises a material selected from the group consisting of diphenylmethane diisocyanate, a polymeric isomer of diphenylmethane diisocyanate, and combinations thereof.

27. The lineal of claim 25, wherein the thermosetting polyurethane resin comprises a mold release material and a filler material.

28. The lineal of claim 27, wherein the mold release material is provided in an amount between approximately 0.5% and 5% of the total mass of the thermosetting polyurethane resin.

29. The lineal of claim 27, wherein the filler comprises at least one material selected from the group consisting of caolin clay, calcium carbonate, and combinations thereof.

30. The lineal of claim 25, wherein the thermosetting polyurethane resin has an elastic modulus of between approximately 350,000 and 500,000 psi after curing.

31. The lineal of claim 25, wherein the first polyether polyol has an OH index of between approximately 230 and 250 mgOH/g, the second polyether polyol has an OH index of between approximately 600 and 700 mgOH/g, and the third polyether polyol has an OH index of between approximately 900 and 1100 mgOH/g.

32. The lineal of claim 25, wherein the first polyether polyol has a viscosity of less than approximately 500 cps, the second polyether polyol has a viscosity of less than approximately 1000 cps, and the third polyether polyol has a viscosity of less than approximately 2000 cps.

33. The lineal of claim 25, wherein the first polyether polyol has a viscosity of less than approximately 400 cps, the second polyether polyol has a viscosity of less than approximately 900 cps, and the third polyether polyol has a viscosity of less than approximately 1500 cps.

34. The lineal of claim 25, wherein the first polyether polyol has a molecular weight of between approximately 650 and 750, the second polyether polyol has a molecular weight of between approximately 225 and 275, and the third polyether polyol has a molecular weight of between approximately 125 and 200.

35. The lineal of claim 25, wherein the polyol component comprises between approximately 25% and 35% of the first polyether polyol, between approximately 25% and 35% of the second polyether polyol, and between approximately 30% and 45% of the third polyether polyol.

36. The lineal of claim 25, wherein the fiber tows comprise fibers that are selected from the group consisting of glass fibers, polymeric fibers, carbon fibers, and combinations thereof.

37. The lineal of claim 36, wherein the lineal has a longitudinal axis and a transverse axis, and the fibers are oriented substantially parallel to the longitudinal axis.

38. The lineal of claim 25, wherein the thermosetting polyurethane resin further comprises a polymeric additive configured to counteract shrinkage of the resin composition during polymerization.

39. A pultruded composite component comprising:

a matrix material comprising a thermosetting polyurethane resin; and

fibers provided within the resin matrix;

wherein all of the fibers within the matrix material are oriented in substantially a single direction and the matrix material has an elongation-to-failure that exceeds that of the fibers;

wherein the matrix material comprises;

an isocyanate material comprising a material selected from the group consisting of diphenylmethane diisocyanate, a polymeric isomer of diphenylmethane diisocyanate, and combinations thereof;

a first polyether polyol having a functionality of at least three and a molecular weight of between approximately 600 and 800;

a second polyether polyol having a functionality of at least three and a molecular weight of between approximately 200 and 300;

a third polyether polyol having a functionality of at least three and a molecular weight of between approximately 100 and 300;

a mold release material; and

a filler material;

wherein the first, second, and third polyether polyols are provided as a blend comprising between approximately 20% and 50% of the first polyether polyol, between approximately 20 and 40% of the second polyether polyol, and between approximately 20 and 50% of the third polyether polyol.

40. The pultruded composite component of claim 39, wherein the first polyether polyol has a viscosity below approximately 500 cps, the second polyether polyol has a viscosity below approximately 1,000 cps, and the third polyether polyol has a viscosity below approximately 2,000 cps.

41. The pultruded composite component of claim 39, wherein the blend has an OH index of between approximately 350 and 700 mgOH/g.

42. The pultruded composite component of claim 41, wherein the first polyether polyol has a viscosity below approximately 500 cps, the second polyether polyol has a viscosity below approximately 1,000 cps, and the third polyether polyol has a viscosity below approximately 2,000 cps.

43. The pultruded composite component of claim 41, wherein the blend comprises between approximately 25% and 35% of the first polyether polyol, between approximately 25% and 35% of the second polyether polyol, and between approximately 30% and 45% of the third polyether polyol.

44. The pultruded composite component of claim 39, wherein the first polyether polyol has an OH index of between approximately 230 and 250 mgOH/g, the second polyether polyol has an OH index of between approximately 600 and 700 mgOH/g, and the third polyether polyol has an OH index of between approximately 900 and 1100 mgOH/g.

45. The pultruded composite component of claim 39, wherein the pultruded composite component is a lineal for a window or door.