CA2447745C - Pultrusion forming of foamed panels - Google Patents
Pultrusion forming of foamed panels Download PDFInfo
- Publication number
- CA2447745C CA2447745C CA 2447745 CA2447745A CA2447745C CA 2447745 C CA2447745 C CA 2447745C CA 2447745 CA2447745 CA 2447745 CA 2447745 A CA2447745 A CA 2447745A CA 2447745 C CA2447745 C CA 2447745C
- Authority
- CA
- Canada
- Prior art keywords
- box structure
- foam
- panel
- caterpillar
- die
- 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.)
- Expired - Fee Related
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]
- B29C70/52—Pultrusion, i.e. forming and compressing by continuously pulling through a die
- B29C70/525—Component parts, details or accessories; Auxiliary operations
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
- B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
A foam filled plastic panel is formed through a pultrusion process. A moldable panel wall forming material is pulled by a caterpillar pullet through a die to produce a box structure. As the box structure is pulled into the caterpillar pullet a foam forming mixture is injected into the box like structure. The foam foaming mixture expands to produce a foam filler within the box structure which urges outward expansion of the box structure onto the interior grip region of the caterpillar pullet. The expanding of the foam forming mixture further prevents inward collapsing of the box structure which is under pressure while it is being puller through the caterpillar puller.
Description
PULTRUSION FORMING OF FOAMED PANELS
FIELD OF THE INVENTION
The present invention relates to a pultrusion method of forming a foam filled panel.
BACKGROUND OF THE INVENTION
Foam filled panels having an exterior molded skin filled with foam material such as polyurethane foam or the like are becoming more and more popular in different building applications. These types of panels are particularly useful because they are relatively light in weight while being extremely sturdy and rigid.
According to known practice, foam filled panels are made an injection molding process.
When making a continuous length of panel which is then cut into shorter panel sections most panel forming methods use an extrusion process. Another process which is available but which is used to a lesser extent in the formation of hollow panels is a pultrusion process. The pultrusion process produces highly accurately shaped product but is typically very slow in production. To date pultrusion processes have not been used in the formation of foam filled panels because of the slow production rate and also because the conventional pultrusion process is not conducive to the loading of a panel with foam material.
SUMMARY OF THE PRESENT INVENTION
The present invention is one which takes advantage of the benefits of panel forming using a pultrusion process without suffering from the slow production rate of a conventional pultrusion process and at the same time enabling the injection of foam material into a molded pultrusion formed plastic panel.
More particularly, the present invention provides a method of pultrusion forming a foam filled molded panel. The method comprises pulling a moldable panel wall forming material into a die by means of a caterpillar pulley having interior grip region located downstream of the die. The caterpillar pulley is one of the key aspects of the present invention.
The panel wall forming material is shaped into a hollow box structure within the die. After the hollow box structure leaves the die a foam forming mixture is injected into the hollow box structure as the box structure is pulled by the caterpillar into the interior grip region of the pulley.
The foam forming mixture expands interiorly of the box structure within the caterpillar pulley to produce a foam filler within the box structure. The expansion of the foam forming mixture also urges outward expansion of the box structure onto the interior grip region of the caterpillar pulley and prevents inward collapsing of the box structure within the caterpillar pulley.
According to an aspect of the invention strips or strands of reinforcing material are additionally pulled with the box structure into the caterpillar pulley. The foam forming mixture expands around these reinforcing strips or strands to hold them in place within the foam filled panel.
According to another aspect of the invention the box like structure is shaped within the die to include slots for receiving reinforcing inserts which are later slid into position along an exterior surface of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;
Figure 1 is schematic view of a panel forming line according to a preferred embodiment of the present invention;
Figure 2 is an enlarged sectional view through the die of the panel forming line of Figure 1;
Figure 3 is an enlarged sectional view through the caterpillar pulley of the line of Figure 1;
Figure 4 is a schematic view of panel forming line according to a further preferred embodiment of the present invention;
Figure 5 is sectional view through the die of the line of Figure 4;
Figure 6 is an enlarged sectional view through the caterpillar pulley of the line of Figure Figures 7 through 9 are sectional views through different panel constructions made according to different preferred embodiments of the present invention.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INSTENTION IN WHICH:
Figure 1 shows a foam panel forming line or system generally indicated at 1. This line comprises a supply 3 of panel wall or skin forming material. This material is one which has properties enabling the material to be formed to a desired shape in a molding process. They are presently available many different types of materials used in panel formation and essentially all of those materials are useable according to the present invention.
A particular desirable material is one which comprises about 80~ of glass fiber carried by about 20~ of a plastic carrier material. This material composition is strong, relatively resistant to temperature changes and is light in weight.
The skin or panel wall forming material 5 is removed from supply 3 in a pultrusion method. The source of pull according to this method is a caterpillar pulley 13 located near the downstream end of line 1.
As better seen for example in Figure 3 of the drawings caterpillar pulley 13 comprises a pair of endless belts having interior runs or belts portions 21 which define an interior grip region for the caterpillar pulley.
The actual passage of the panel as it is formed while being pulled through the caterpillar pulley will be described later in greater detail. However, from a general standpoint it will be seen that caterpillar pulley 13 acts as a pulling agent to pull the material 5 from the supply source 3 through a treatment vat 7. This treatment vat coats the material 5 with surface treatments as are known in the art to further enhance the durability and weather resistant features of the panel wall forming material.
After the material leaves vat 7 it is pulled, once again by the caterpillar pulley 13 into a die 9. This die is used to shape the material 5 into a hollow box structure 5a which is shown leaving the downstream region of the die.
The system uses the pulling power of the caterpillar pulley to pull the material 5 onto the interior surface walls of the die. This provides accurate placement of the material onto the internal die surfaces in shaping the hollow box structure 5a.
Shaping dies are used in conventional pultrusion processes. However, these shaping dies are typically extremely short in length and necessitate a very slow pulling of the material in order to have the material setup and hold shape within such a short traditional die e.g., a die of about 2 to 4 feet in length.
According to the present invention die 9 is an extremely long die in comparison to known prior art dies.
According to a preferred embodiment of the present invention die 9 is anywhere from 6 to 8 feet in length which allows a production rate of about 22 to 30 feet per minute. This rate is very high in the pultrusion art.
At this length the material can be pulled much more quickly through the die and still have an opportunity to properly set its shape prior to leaving the die.
Figure 3 shows the box structure 5a after it has been sufficiently set to hold shape before entering the caterpillar puller 13. A very key part to the present invention occurs at this particular point.
More specifically, having reference to both Figures 2 and 3 it will be seen that line 1 further includes a source of foam producing material 11. This source of material comprises a mixture of two foam forming agents which are inert when separated from one another. However, once the agents are mixed and react to one another they almost instantaneously expand into a cellular foam construction which is again something that is known to those skilled in the foaming art. Such foams have been used for example in the production of insulating jackets within hot water heaters and the like.
According to the present invention the foam supply 11 feeds along a supply line 15 which penetrates through the panel wall forming material 5 before the material enters die 9. Any penetration opening made by supply line 15 is completely closed as the panel walls are formed within die 9.
With the above setup it will be seen in Figure 2 that the supply line 15 from the foam material source 11 is contained within the hollow box structure 5a at the downstream end of die 9.
The supply line 15 continues all the way to the upstream end of the caterpillar pulley 13 as shown in Figure 3 of the drawings. Line 15 terminates with a spray nozzle 17. The foam forming mixture is sprayed from nozzle 17 as the mixture is expanding where the box structure 5a enters the interior grip region of the caterpillar pulley. The mixture immediately sets up to produce a foam filler 23 within the box structure now trapped in the caterpillar pulley.
At this point a number of features of the present invention simultaneously occur. The foarri filler 23 expands within the box structure as a panel foam filler.
The expansion of the foam material produces an outward biasing effect on the walls of the box structure causing the box structure to positively engage the interior runs 21 of caterpillar pulley 13. This provides a pressurized friction grip between the wall of the box structure and the grip surfaces of the caterpillar pulley. In addition, it prevents the box structure from collapsing inwardly while the box structure is under pressure from the caterpillar which presses on the walls of the box structure as the box structure is being pulled through the caterpillar. The box structure then leaves the caterpillar pulley as a foam filled panel 5b shown at the downstream end of Figure 3. From here the continuous length of panel formed to this point can be cut into different panel lengths according to the desired use for the panel.
It should be noted that the foam material when expanding according to the present invention is not controlled lengthwise of the panel other than through the fact that the foam material hardens extremely quickly.
To this end the caterpillar pulley preferably has a length of about 40 feet which is sufficiently long to ensure that foam hardens while the panel is trapped in the caterpillar pulley.
Figure 4 of the drawings shows a slightly modified panel production line 1A. This production line uses the same supply source 3, the same treatment vat 7, the same shaping die 9 and the same caterpillar pulley 13 as that found in line 1 described above. What differs between line 1 and line 1a is that the latter line further includes an additional pulling station 25 for pulling reinforcing means which in this particular case are strands of reinforcing fiber material 27 through the panel as the panel is being formed in the pultrusion process. The strands of material 27 are pulled off of supply drums 26 at the upstream end of die 9 and around which the box structure is formed as shown in Figure 5 of the drawings.
The reinforcing strands 27 are kept under tension between the supply drums 26 and the pulling station 25 making them taut and keeping them properly aligned within the panel which according to Figure 4 leaves the caterpillar pulley as a continuous panel 5c. Panel 5c as shown in Figures 6 and 7 of the drawings once again contains the foam filler 23. This filler forms around the strands 27 permanently locating them in place within the foam filled reinforced panel 5c.
Figure 8 of the drawings shows a further panel construction 5d which also has a foam filler 23.
However, rather than having interior reinforcing strands panel 5d includes interior reinforcing strips 31 which are preferably of a metal construction. These strips are once again formed permanently within the foam filler of panel 5d.
Figure 9 of the drawings shows a further panel construction 5e. This panel construction like the earlier constructions comprises a foam filler 23 covered by a box like skin or panel wall. However, in the Figure 9 embodiment the panel rather than containing permanent interior reinforcement means is shaped on its exterior surface with a plurality of undercut slots 33. These slots are formed at the die stage of the forming process.
They are used to receive reinforcing inserts which slide into position within the undercut slots. Preferably these inserts are replaceable should they become damaged or fatigued. The external location of the inserts easily allows them to be exchanged with further inserts.
A11 of the panels shown in Figures 7 through 9 of the drawings have opposite ends which allow mating of the panels with correspondingly shaped panels. For instance, in Figure 9 panel 5e has a first end 39 and a second end 41. The end 39 of panel 5e is shaped to mate with a further panel having the same shape i.e., a panel having a panel end 41 to which panel end 39 will match.
As will also be seen in Figure 9 of the drawings the insert receiving slot formed at panel end 39 comprises a slot part 35 while panel end 41 is provided with a further slot part 37. Slot parts 35 and 37 when mated with one another at aligned interlocked panels will once again produce the slot shape 33 for receiving one of the replaceable inserts at the juncture between two panels. This insert helps to lock the panels end to end with one another.
Many different uses can be made of any one of the panels shown in the drawings, or any other panels having the foamed pulltruted construction of the present invention. One particularly suitable use for these panels is in the construction of large truck trailer bodies. The panels easily assemble with one another in forming the truck trailer body and they stand up to the abuse to which these truck trailer bodies are normally exposed. Furthermore, a truck trailer body made using the foamed panel construction of the present invention is extremely light in weight in comparison to its highly durable strong nature.
Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
FIELD OF THE INVENTION
The present invention relates to a pultrusion method of forming a foam filled panel.
BACKGROUND OF THE INVENTION
Foam filled panels having an exterior molded skin filled with foam material such as polyurethane foam or the like are becoming more and more popular in different building applications. These types of panels are particularly useful because they are relatively light in weight while being extremely sturdy and rigid.
According to known practice, foam filled panels are made an injection molding process.
When making a continuous length of panel which is then cut into shorter panel sections most panel forming methods use an extrusion process. Another process which is available but which is used to a lesser extent in the formation of hollow panels is a pultrusion process. The pultrusion process produces highly accurately shaped product but is typically very slow in production. To date pultrusion processes have not been used in the formation of foam filled panels because of the slow production rate and also because the conventional pultrusion process is not conducive to the loading of a panel with foam material.
SUMMARY OF THE PRESENT INVENTION
The present invention is one which takes advantage of the benefits of panel forming using a pultrusion process without suffering from the slow production rate of a conventional pultrusion process and at the same time enabling the injection of foam material into a molded pultrusion formed plastic panel.
More particularly, the present invention provides a method of pultrusion forming a foam filled molded panel. The method comprises pulling a moldable panel wall forming material into a die by means of a caterpillar pulley having interior grip region located downstream of the die. The caterpillar pulley is one of the key aspects of the present invention.
The panel wall forming material is shaped into a hollow box structure within the die. After the hollow box structure leaves the die a foam forming mixture is injected into the hollow box structure as the box structure is pulled by the caterpillar into the interior grip region of the pulley.
The foam forming mixture expands interiorly of the box structure within the caterpillar pulley to produce a foam filler within the box structure. The expansion of the foam forming mixture also urges outward expansion of the box structure onto the interior grip region of the caterpillar pulley and prevents inward collapsing of the box structure within the caterpillar pulley.
According to an aspect of the invention strips or strands of reinforcing material are additionally pulled with the box structure into the caterpillar pulley. The foam forming mixture expands around these reinforcing strips or strands to hold them in place within the foam filled panel.
According to another aspect of the invention the box like structure is shaped within the die to include slots for receiving reinforcing inserts which are later slid into position along an exterior surface of the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The above as well as other advantages and features of the present invention will be described in greater detail according to the preferred embodiments of the present invention in which;
Figure 1 is schematic view of a panel forming line according to a preferred embodiment of the present invention;
Figure 2 is an enlarged sectional view through the die of the panel forming line of Figure 1;
Figure 3 is an enlarged sectional view through the caterpillar pulley of the line of Figure 1;
Figure 4 is a schematic view of panel forming line according to a further preferred embodiment of the present invention;
Figure 5 is sectional view through the die of the line of Figure 4;
Figure 6 is an enlarged sectional view through the caterpillar pulley of the line of Figure Figures 7 through 9 are sectional views through different panel constructions made according to different preferred embodiments of the present invention.
DETAILED DESCRIPTION ACCORDING TO THE PREFERRED
EMBODIMENTS OF THE PRESENT INSTENTION IN WHICH:
Figure 1 shows a foam panel forming line or system generally indicated at 1. This line comprises a supply 3 of panel wall or skin forming material. This material is one which has properties enabling the material to be formed to a desired shape in a molding process. They are presently available many different types of materials used in panel formation and essentially all of those materials are useable according to the present invention.
A particular desirable material is one which comprises about 80~ of glass fiber carried by about 20~ of a plastic carrier material. This material composition is strong, relatively resistant to temperature changes and is light in weight.
The skin or panel wall forming material 5 is removed from supply 3 in a pultrusion method. The source of pull according to this method is a caterpillar pulley 13 located near the downstream end of line 1.
As better seen for example in Figure 3 of the drawings caterpillar pulley 13 comprises a pair of endless belts having interior runs or belts portions 21 which define an interior grip region for the caterpillar pulley.
The actual passage of the panel as it is formed while being pulled through the caterpillar pulley will be described later in greater detail. However, from a general standpoint it will be seen that caterpillar pulley 13 acts as a pulling agent to pull the material 5 from the supply source 3 through a treatment vat 7. This treatment vat coats the material 5 with surface treatments as are known in the art to further enhance the durability and weather resistant features of the panel wall forming material.
After the material leaves vat 7 it is pulled, once again by the caterpillar pulley 13 into a die 9. This die is used to shape the material 5 into a hollow box structure 5a which is shown leaving the downstream region of the die.
The system uses the pulling power of the caterpillar pulley to pull the material 5 onto the interior surface walls of the die. This provides accurate placement of the material onto the internal die surfaces in shaping the hollow box structure 5a.
Shaping dies are used in conventional pultrusion processes. However, these shaping dies are typically extremely short in length and necessitate a very slow pulling of the material in order to have the material setup and hold shape within such a short traditional die e.g., a die of about 2 to 4 feet in length.
According to the present invention die 9 is an extremely long die in comparison to known prior art dies.
According to a preferred embodiment of the present invention die 9 is anywhere from 6 to 8 feet in length which allows a production rate of about 22 to 30 feet per minute. This rate is very high in the pultrusion art.
At this length the material can be pulled much more quickly through the die and still have an opportunity to properly set its shape prior to leaving the die.
Figure 3 shows the box structure 5a after it has been sufficiently set to hold shape before entering the caterpillar puller 13. A very key part to the present invention occurs at this particular point.
More specifically, having reference to both Figures 2 and 3 it will be seen that line 1 further includes a source of foam producing material 11. This source of material comprises a mixture of two foam forming agents which are inert when separated from one another. However, once the agents are mixed and react to one another they almost instantaneously expand into a cellular foam construction which is again something that is known to those skilled in the foaming art. Such foams have been used for example in the production of insulating jackets within hot water heaters and the like.
According to the present invention the foam supply 11 feeds along a supply line 15 which penetrates through the panel wall forming material 5 before the material enters die 9. Any penetration opening made by supply line 15 is completely closed as the panel walls are formed within die 9.
With the above setup it will be seen in Figure 2 that the supply line 15 from the foam material source 11 is contained within the hollow box structure 5a at the downstream end of die 9.
The supply line 15 continues all the way to the upstream end of the caterpillar pulley 13 as shown in Figure 3 of the drawings. Line 15 terminates with a spray nozzle 17. The foam forming mixture is sprayed from nozzle 17 as the mixture is expanding where the box structure 5a enters the interior grip region of the caterpillar pulley. The mixture immediately sets up to produce a foam filler 23 within the box structure now trapped in the caterpillar pulley.
At this point a number of features of the present invention simultaneously occur. The foarri filler 23 expands within the box structure as a panel foam filler.
The expansion of the foam material produces an outward biasing effect on the walls of the box structure causing the box structure to positively engage the interior runs 21 of caterpillar pulley 13. This provides a pressurized friction grip between the wall of the box structure and the grip surfaces of the caterpillar pulley. In addition, it prevents the box structure from collapsing inwardly while the box structure is under pressure from the caterpillar which presses on the walls of the box structure as the box structure is being pulled through the caterpillar. The box structure then leaves the caterpillar pulley as a foam filled panel 5b shown at the downstream end of Figure 3. From here the continuous length of panel formed to this point can be cut into different panel lengths according to the desired use for the panel.
It should be noted that the foam material when expanding according to the present invention is not controlled lengthwise of the panel other than through the fact that the foam material hardens extremely quickly.
To this end the caterpillar pulley preferably has a length of about 40 feet which is sufficiently long to ensure that foam hardens while the panel is trapped in the caterpillar pulley.
Figure 4 of the drawings shows a slightly modified panel production line 1A. This production line uses the same supply source 3, the same treatment vat 7, the same shaping die 9 and the same caterpillar pulley 13 as that found in line 1 described above. What differs between line 1 and line 1a is that the latter line further includes an additional pulling station 25 for pulling reinforcing means which in this particular case are strands of reinforcing fiber material 27 through the panel as the panel is being formed in the pultrusion process. The strands of material 27 are pulled off of supply drums 26 at the upstream end of die 9 and around which the box structure is formed as shown in Figure 5 of the drawings.
The reinforcing strands 27 are kept under tension between the supply drums 26 and the pulling station 25 making them taut and keeping them properly aligned within the panel which according to Figure 4 leaves the caterpillar pulley as a continuous panel 5c. Panel 5c as shown in Figures 6 and 7 of the drawings once again contains the foam filler 23. This filler forms around the strands 27 permanently locating them in place within the foam filled reinforced panel 5c.
Figure 8 of the drawings shows a further panel construction 5d which also has a foam filler 23.
However, rather than having interior reinforcing strands panel 5d includes interior reinforcing strips 31 which are preferably of a metal construction. These strips are once again formed permanently within the foam filler of panel 5d.
Figure 9 of the drawings shows a further panel construction 5e. This panel construction like the earlier constructions comprises a foam filler 23 covered by a box like skin or panel wall. However, in the Figure 9 embodiment the panel rather than containing permanent interior reinforcement means is shaped on its exterior surface with a plurality of undercut slots 33. These slots are formed at the die stage of the forming process.
They are used to receive reinforcing inserts which slide into position within the undercut slots. Preferably these inserts are replaceable should they become damaged or fatigued. The external location of the inserts easily allows them to be exchanged with further inserts.
A11 of the panels shown in Figures 7 through 9 of the drawings have opposite ends which allow mating of the panels with correspondingly shaped panels. For instance, in Figure 9 panel 5e has a first end 39 and a second end 41. The end 39 of panel 5e is shaped to mate with a further panel having the same shape i.e., a panel having a panel end 41 to which panel end 39 will match.
As will also be seen in Figure 9 of the drawings the insert receiving slot formed at panel end 39 comprises a slot part 35 while panel end 41 is provided with a further slot part 37. Slot parts 35 and 37 when mated with one another at aligned interlocked panels will once again produce the slot shape 33 for receiving one of the replaceable inserts at the juncture between two panels. This insert helps to lock the panels end to end with one another.
Many different uses can be made of any one of the panels shown in the drawings, or any other panels having the foamed pulltruted construction of the present invention. One particularly suitable use for these panels is in the construction of large truck trailer bodies. The panels easily assemble with one another in forming the truck trailer body and they stand up to the abuse to which these truck trailer bodies are normally exposed. Furthermore, a truck trailer body made using the foamed panel construction of the present invention is extremely light in weight in comparison to its highly durable strong nature.
Although various preferred embodiments of the present invention have been described in detail, it will be appreciated by those skilled in the art that variations may be made without departing from the spirit of the invention or the scope of the appended claims.
Claims (7)
1. A method of pultrusion forming a foam filled molded panel, said method comprising pulling a moldable panel wall forming material into a die by means of a caterpillar puller having an interior grip region located downstream of the die, shaping the panel wall forming material into a hollow box structure within the die, injecting a foam forming mixture into the hollow box structure as the box structure is pulled by the caterpillar puller into the interior grip region of the caterpillar puller and expanding the foam forming mixture interiorly of the box structure in the caterpillar puller to produce a foam filler within the box structure which urges outward expansion of the box structure onto the interior grip region of the caterpillar puller and which prevents inward collapsing of the box structure which is under pressure while being pulled through the caterpillar puller.
2. A method as claimed in Claim 1 wherein the panel wall forming material is formed from a glass and plastic composition.
3. A method as claimed in Claim 1 wherein said foam filler comprises a polyurethane foam material.
4. A method as claimed in Claim 1 further including pulling reinforcing material into said hollow box structure before injecting the foam forming mixture therein, the foam mixture then expanding around and containing the reinforcing material within the foam filler of the box structure.
5. A method as claimed in Claim 4 wherein the reinforcing insert material comprises strands of reinforcing fiber material which are pulled taut within the box structure to ensure alignment of the strands within the foam filler.
6. A method as claimed in Claim 1 wherein the box structure is shaped within the die to include slots for receiving replaceable reinforcing inserts along an exterior surface of the panel.
7. A method as claimed in Claim 6 including sliding the reinforcing inserts into said slots.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2447745 CA2447745C (en) | 2003-11-03 | 2003-11-03 | Pultrusion forming of foamed panels |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2447745 CA2447745C (en) | 2003-11-03 | 2003-11-03 | Pultrusion forming of foamed panels |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2447745A1 CA2447745A1 (en) | 2005-05-03 |
| CA2447745C true CA2447745C (en) | 2009-01-20 |
Family
ID=34558289
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2447745 Expired - Fee Related CA2447745C (en) | 2003-11-03 | 2003-11-03 | Pultrusion forming of foamed panels |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2447745C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102011103230A1 (en) | 2011-06-03 | 2012-12-06 | Daimler Ag | Pultrusion tool for fiber-reinforced plastic hollow profile, comprises molding and curing zone comprising molding core and heating device, foaming zone present downstream to molding and curing zone, and supply line for foamable composition |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| BE1020128A3 (en) * | 2011-08-02 | 2013-05-07 | Oroplastic Nv | METHOD AND A DEVICE FOR MANUFACTURING INSULATION PANELS. |
| EP2626193B1 (en) * | 2011-12-07 | 2017-03-22 | Fiberline A/S | Method for producing fibre reinforced structural elements having insulating capabilities |
| EP2641726A1 (en) * | 2012-03-21 | 2013-09-25 | Fiberline A/S | Method and apparatus for preventing thermal bridges in fibre reinforced structural elements |
| DE102014001082A1 (en) * | 2014-01-30 | 2015-07-30 | Thomas Gmbh + Co. Technik + Innovation Kg | Method and device for producing thin-walled plastic profiles |
| CN111216266A (en) * | 2019-12-04 | 2020-06-02 | 中航复合材料有限责任公司 | Preparation method of three-dimensional fiber preform based on fiber seam laying process |
-
2003
- 2003-11-03 CA CA 2447745 patent/CA2447745C/en not_active Expired - Fee Related
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102011103230A1 (en) | 2011-06-03 | 2012-12-06 | Daimler Ag | Pultrusion tool for fiber-reinforced plastic hollow profile, comprises molding and curing zone comprising molding core and heating device, foaming zone present downstream to molding and curing zone, and supply line for foamable composition |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2447745A1 (en) | 2005-05-03 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US5876641A (en) | In-line process for injection of foam material into a composite profile | |
| US6440339B1 (en) | Method of making a corded earplug | |
| US8663514B2 (en) | Gas-assisted co-injection molded chair | |
| KR20030040544A (en) | Method and apparatus for making a shaving razor handle | |
| CA2277445A1 (en) | Method for making foam filled doors and apparatus therefor | |
| KR20000022359A (en) | Manufacture of foam-containing composites | |
| CA2447745C (en) | Pultrusion forming of foamed panels | |
| DE60103871D1 (en) | METHOD AND APPARATUS FOR THE PRODUCTION OF DETERGENT AND DETERGENT PIECES | |
| TW200609281A (en) | A method for the manufacture of a foamed polymer body | |
| JPS6427924A (en) | Method for manufacturing synthetic substance mixture, which can be foamed, and extruder line | |
| KR970005577A (en) | Process for producing polyurethane foamed molded article | |
| DE60209181D1 (en) | Process for the production of foam moldings | |
| US20110052904A1 (en) | Pultrusion process and related article | |
| JP3989322B2 (en) | Manufacturing method of RIM molded product | |
| DE2000737C3 (en) | Process for the production of foamed plastics | |
| WO2004065742A3 (en) | Part foam components | |
| DE19525663C1 (en) | Prodn. of polyurethane foam mouldings | |
| WO1999012724A1 (en) | Method for producing foamed plastic hollow bodies | |
| CA2408389A1 (en) | Method for producing a structure made of composite material for railway vehicles | |
| EP1645386A1 (en) | Method for producing lightweight structural components | |
| IT1173419B (en) | Continuous prodn. of skinned polyurethane or other profiles | |
| JP2749670B2 (en) | PROCESS FOR PRODUCING PIPE FORM COMPRISING HEAT-FOAMABLE RESIN COMPOSITION | |
| ATE253441T1 (en) | METHOD FOR PRODUCING SANDWICH ELEMENTS WITH POLYURETHANE FOAM CORE (PUR) | |
| JP4489751B2 (en) | Manufacturing method of RIM molded product | |
| EP1645384A1 (en) | Method for producing lightweight structural components |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDC | Correction of dead application (reinstatement) | ||
| MKLA | Lapsed |