Method and apparatus for forming in-line core-filled pultruded profiles

Claim 3

A method as claimed in claim 1 wherein the core-forming materials comprise particulate matter.

Claim 4

A method as claimed in claim 2, wherein the particulate matter is of substantially uniform grain size.

Claim 5

A method as claimed in claim 3, wherein the core forming materials are progressively conformed to the cross-sectional shape of the resin-curing die as the materials approach the die station through the duct.

Claim 6

A method as claimed in claim 1, further comprising providing a pre-die former in advance of and spaced from said resin-curing die, said pre-die former having a cross-sectional shape which is similar to but oversize in relation to the resin-curing die, and blowing the core-forming materials through the pre-die former to emerge from the former in compacted form to form a slightly enlarged wall encased in said cloth moving towards said resin-curing die.

Claim 7

Apparatus for manufacturing pultruded profiles having a core resin-bonded to a skin, comprising: (a) a pultrusion die station defining an inlet and an outlet and including a resin-curing die defining a cross-sectional shape for determining the cross-sectional shape of a profile; (b) an elongate hollow duct extending towards the die station inlet having a first end remote from the resin curing die and a second end closer to the resin-curing die, and an external shape which changes progressively from the first end to the second end, and at the second end is similar in cross-section but oversize in relation to the cross-sectional shape of the resin-curing die; (c) first feeding means comprising an air blower for feeding core forming materials to the die station inlet through the duct by an air stream; (d) second feeding means for separately feeding skin forming materials, in the form of at least one run of cloth to the die station inlet; (e) guide means for guiding the cloth over the outer surface of the duct and progressively guiding the cloth to conform to the cross-sectional shape of the resin-curing die as the cloth run approaches the die station, the guide means being spaced from the die station inlet; (f) third feeding station means for introducing bonding resin to the die station; and (g) pulling means for pulling an in-line cored resin-bonded profile from the die station outlet; whereby said apparatus is adapted to manufacture pultruded profiles having a skin comprising cloth so that the pultruded profiles have improved two-dimensional strength.

Claim 8

Apparatus for manufacturing pultruded profiles having a core resin-bonded to a skin, comprising: (a) a pultrusion die station defining an inlet and an outlet and including a resin-curing die defining a cross-sectional shape for determining the cross-sectional shape of a profile; (b) an elongate hollow duct extending towards the die station inlet having a first end remote from the resin curing die and a second end closer to the resin-curing die, and an external shape which changes progressively from the first end to the second end, and at the second end is similar in cross-section but oversize in relation to the cross-sectional shape of the resin-curing die; (c) first feeding means comprising an air blower for feeding core forming materials to the die station inlet through the duct by an air stream; (d) second feeding means for separately feeding skin forming materials, in the form of at least one run of cloth to the die station inlet; (e) guide means for guiding the cloth over the outer surface of the duct and progressively guiding the cloth to conform to the cross-sectional shape of the resin-curing die as the cloth run approaches the die station, the guide means being spaced from the die station inlet; (f) third feeding station means for introducing bonding resin to the die station; and (g) pulling means for pulling an in-line cored resin-bonded profile from the die station outlet; whereby said apparatus is adapted to manufacture pultruded profiles having a skin comprising cloth so that the pultruded profiles have improved two-dimensional strength.

Claim 9

An apparatus as claimed in claim 6, wherein the inner surface of the duct conforms progressively along its length to the cross-sectional shape of the resin-curing die.

Claim 10

An apparatus as claimed in claim 6, wherein the die station comprises a forming die in advance of and spaced from said resin-curing die; said forming die having a cross-sectional shape which is similar to but oversize in relation to the resin-curing die.

Claim 11

An apparatus as claimed in claim 8, wherein said forming die is tapered along its length being of greater cross-section at its input end than at its output end.

Claim 12

An apparatus as claimed in claim 6 wherein said air blower means comprises a venturi blower to provide an air stream for blowing the core-forming materials, provided in the form of particulate matter across the cross-sectional shape defined by the duct.

Claim 13

An apparatus as claimed in claim 6, wherein the guide means includes a pre-die former located around the duct in the proximity of the second end of the duct and having a cross-sectional shape which is similar to but oversize in relation to the resin-curing die.

Claim 14

An apparatus as claimed in claim 11, wherein said pre-die former is tapered along its length being of greater cross-section at its input end than at its output end.