WO2022081023A1

WO2022081023A1 - Diebed carriage and method of positioning a diebed

Info

Publication number: WO2022081023A1
Application number: PCT/NZ2021/050140
Authority: WO
Inventors: David Gordon PICKEN
Original assignee: Pultron Composites Limited
Priority date: 2020-10-14
Filing date: 2021-08-20
Publication date: 2022-04-21

Abstract

A first interchangeable diebed carriage 50 for a pultrusion apparatus 200 has a carriage body 51 with a diebed 53 for receipt of, or coupled to, a first die 55. The diebed carriage 50 has a movement arrangement 57 configured such that the diebed carriage 50 is movable to a position within the pultrusion apparatus 200 for use of the first 55 die during a pultrusion process. The diebed carriage 50 is removable from the position within the pultrusion apparatus 200 and replaceable with a second interchangeable diebed carriage 70 having a movement arrangement 77 and a carriage body 72 having a diebed 74 coupled to a second die 75, for use of the second die during a pultrusion process. A pultrusion apparatus 200 and pultrusion method are also provided.

Description

DIEBED CARRIAGE AND METHOD OF POSITIONING A DIEBED

FIELD OF THE INVENTION

This invention relates to a diebed carriage and method of positioning a diebed carriage.

BACKGROUND

In a standard pultrusion process, materials such as fibres, woven or braided strands and the like are formed into reinforced products, for example composite rebar rods for use in construction. A continuous length of the material is first impregnated with resin and then pulled through a heated die where the resin undergoes curing. Once cured, the formed product is pulled through a severing device which severs the continuous length of formed product into discrete lengths.

Pultrusion dies require correct alignment to ensure the product is formed correctly. Further, they must be clamped securely against the pulling forces imparted on the dies during the pultrusion process. As such, when a new die is desired in order to produce a different product, the entire pultrusion process must be halted as a different die is swapped over, aligned and clamped, resulting in significant downtime.

It is an object of at least preferred embodiments of the present invention to provide a diebed carriage and method of positioning a diebed that addresses at least one of the issues outlined above, and/or to at least provide the public with a useful alternative.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided a first interchangeable diebed carriage for a pultrusion apparatus, the first interchangeable diebed carriage comprising: a carriage body comprising a diebed for receipt of, or coupled to, a first die; and a movement arrangement configured such that the diebed carriage is movable to a position within the pultrusion apparatus for use of the first die during a pultrusion process, wherein the first interchangeable diebed carriage is removable from the position within the pultrusion apparatus and replaceable with a second interchangeable diebed carriage comprising a movement arrangement and a carriage body comprising a diebed coupled to a second die, for use of the second die during a pultrusion process.

In some embodiments, the first interchangeable diebed carriage is configured such that as the first interchangeable diebed carriage is moved into the position within the pultrusion apparatus, the first interchangeable diebed carriage is oriented to align the first die into position for use of the first die during the pultrusion process.

In some embodiments, the diebed is configured to orient the first die into position for use of the first die during the pultrusion process.

In some embodiments, the carriage body is configured to removably receive the diebed such that the diebed is replaceable with a different diebed coupled to a different die.

In some embodiments, the diebed is configured to removably receive the first die such that the first die is replaceable with a different die.

In some embodiments, the diebed is configured for receipt of, or is couplable to, a plurality of first dies.

In some embodiments, the pultrusion apparatus and/or the first interchangeable diebed carriage comprises a carriage positioning arrangement configured to position the first interchangeable diebed carriage within the pultrusion apparatus.

In some embodiments, the carriage positioning arrangement comprises at least one actuated member configured to move the first interchangeable diebed carriage into the position within the pultrusion apparatus.

In some embodiments, the carriage positioning arrangement comprises at least one guiding member configured to align the first interchangeable diebed into position within the pultrusion apparatus as it is moved into the position within the pultrusion apparatus.

In some embodiments, the carriage positioning arrangement is configured such that as the first interchangeable diebed carriage is moved into the position within the pultrusion apparatus, the movement arrangement of the first interchangeable diebed carriage is elevated above a support surface.

In accordance with a second aspect of the invention, there is provided a pultrusion apparatus comprising: an upstream fibre delivery section comprising: a fibre source; a resin impregnation device for adding resin to fibre from the fibre source; and a downstream product forming section comprising: at least one pulling device for moving the fibre; and the first interchangeable die bed carriage as outlined above in relation to the first aspect; wherein the first interchangeable diebed carriage is movable to a position within the pultrusion apparatus for use of the first die during a pultrusion process, and wherein the first interchangeable diebed carriage is removable from the pultrusion apparatus and replaceable with a second interchangeable diebed carriage comprising a second die.

In some embodiments, the upstream fibre delivery section is configured to form a plurality of continuous lengths of impregnated fibres, and wherein the at least one pulling device is configured to direct the plurality of continuous lengths of impregnated fibres from the upstream fibre delivery section through the first die when the first interchangeable diebed carriage is in position within the pultrusion apparatus thereby forming a plurality of continuous lengths of a first pultruded product.

In some embodiments, the at least one pulling device is configured to direct the plurality of continuous lengths of impregnated fibres from the upstream fibre delivery section through the second die when the second interchangeable diebed carriage is in position within the pultrusion apparatus thereby forming a plurality of continuous lengths of a second pultruded product.

In some embodiments, the pultrusion apparatus further comprises a product severing station configured to sever the plurality of continuous lengths of the first pultruded product thereby forming a plurality of discrete lengths of the first pultruded product.

In some embodiments, the pultrusion apparatus further comprises a product severing station configured to sever the plurality of continuous lengths of the second pultruded product thereby forming a plurality of discrete lengths of the second pultruded product.

In some embodiments, the second interchangeable diebed carriage comprises a plurality of second dies.

In accordance with a third aspect of the invention, there is provided a pultrusion method comprising the steps of: providing a plurality of continuous lengths of impregnated fibres; directing the plurality of continuous lengths of impregnated fibres through the first die of the first interchangeable diebed carriage as outlined above in relation to the first aspect thereby forming a plurality of continuous lengths of a first pultruded product; replacing the first interchangeable diebed carriage with a second interchangeable diebed carriage comprising a movement arrangement and a carriage body comprising a diebed coupled to a second die; directing the plurality of continuous lengths of impregnated fibres through the second die coupled to the second interchangeable diebed carriage thereby forming a plurality of continuous lengths of a second pultruded product.

In some embodiments, the method further comprises the steps of: directing the plurality of continuous lengths of the first pultruded product through a product severing station thereby forming a plurality of discrete lengths of the first pultruded product; and directing the plurality of continuous lengths of the second pultruded product through the product severing station thereby forming a plurality of discrete lengths of the second pultruded product.

In some embodiments, the diebed of the second interchangeable diebed carriage is coupled to a plurality of second dies.

The term 'comprising' as used in this specification and claims means 'consisting at least in part of'. When interpreting statements in this specification and claims which include the term 'comprising', other features besides the features prefaced by this term in each statement can also be present. Related terms such as 'comprise' and 'comprised' are to be interpreted in a similar manner.

It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7) and, therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner.

This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

As used herein the term '(s)' following a noun means the plural and/or singular form of that noun.

As used herein the term 'and/or' means 'and' or 'or', or where the context allows both. The invention consists in the foregoing and also envisages constructions of which the following gives examples only.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example only and with reference to the accompanying drawings in which:

Figure 1 shows a perspective view of a standard pultrusion apparatus.

Figure 2 shows a side-view of the standard pultrusion apparatus of figure 1.

Figure 3 shows a perspective view of a pultrusion apparatus including an embodiment of the first interchangeable diebed carriage when in use within the pultrusion apparatus.

Figure 4 shows a side-view of the pultrusion apparatus including the embodiment of the first interchangeable diebed carriage of figure 3.

Figure 5 shows a perspective view of a pultrusion apparatus including an embodiment of the first interchangeable diebed carriage when not in use within the pultrusion apparatus.

Figure 6 shows a side-view of the pultrusion apparatus including the embodiment of the first interchangeable diebed carriage of figure 5.

Figure 7 shows a detailed side-view of a pultrusion apparatus including an embodiment of the first interchangeable diebed carriage when in use within the pultrusion apparatus.

Figure 8 shows a perspective view of a pultrusion apparatus including an embodiment of the first interchangeable diebed carriage when in use within the pultrusion apparatus and a second diebed carriage not in use within the pultrusion apparatus.

DETAILED DESCRIPTION OF EMBODIMENTS

In a standard pultrusion process, continuous lengths of material are pulled through a series of sections that sequentially form a composite product. A pultrusion apparatus 100 is shown in figures 1 and 2 and illustrates an example arrangement for manufacturing pultruded products.

The pultrusion apparatus 100 includes several sections comprising devices that are typically used in such a process.

The pultrusion apparatus 100 as shown includes an upstream fibre delivery section 1.

The upstream fibre delivery section 1 itself includes a fibre source and a resin impregnation device for adding resin to fibre from the fibre source. The fibre source (not shown) can comprise, for example, a plurality of continuous lengths of fibres wound around reels. The reels allow the continuous lengths of fibres to be continuously pulled through by pulling devices arranged downstream of the fibre source.

The materials used can include composite fibres, woven or braided strands of fibre-glass, for example, that are formed into tubes, rods, bars or other variously-shaped fibre- reinforced composite products. These products can then be used in a variety of applications where high-tensile strength, light weight and durability are desired such as the construction, marine or spacecraft industries.

The resin impregnation device (not shown) can comprise, for example, a resin bath or a resin-injection chamber which impregnates the continuous lengths of fibres with resin as they pass through the resin impregnation device. Typical resins can include, for example, thermosetting polymers, including polyester and vinylester, or thermoplastics, depending on the fibre material being used and the final product formed.

The pultrusion apparatus 100 also includes at least one pulling device 3 for moving the fibre(s). In the form shown in figures 1-2, the pultrusion apparatus 100 includes two pulling devices 3 which drive the movement of the fibres throughout the pultrusion apparatus 100. The pulling device(s) 3 can comprise, for example, a platten-type hauler or a caterpillar-type hauler, which include motorised rollers that exert a pulling motion on the continuous lengths of fibres.

Once the plurality of continuous lengths of fibres are impregnated with resin, the pulling device(s) 3 direct the plurality of continuous lengths of impregnated fibres 5 through a die 7 that is coupled to a fixed diebed 9. The diebed 9 may also heat the die 7 to an appropriate temperature that causes the resin within the continuous lengths of impregnated fibres to undergo polymerization. The die 7 therefore cures the continuous lengths of impregnated fibres and forms the final shape of the product, thereby forming plurality of continuous lengths of a pultruded product 11.

Figure 1 shows three dies 7 arranged in parallel, as could typically be used in a pultrusion process to create a plurality of continuous lengths of a pultruded product 11. The dies 7 may be comprised of substantially identical dies, i.e., a plurality of dies each forming the same product, or may be comprised of different dies forming different products, or a combination thereof. However, in some configurations, only a single die 7 may be used if desired. The pulling device(s) 3 then direct the plurality of continuous lengths of a pultruded product 11 in a pulling direction indicated by arrow A through a product severing station 13. The product severing station 13 can comprise, for example, a parting saw, or guillotine press, and is configured to sever the plurality of continuous lengths of a pultruded product 11 thereby forming a plurality of discrete lengths of a pultruded product (not shown). The discrete length of the pultruded product may comprise, for example, lengths of fibre-reinforced polymer (FRP) rebar rods.

During the pultrusion process, a high amount of tension is required to ensure a uniformly shaped and formed final product. This tension is created by the pulling device(s) 3 and requires that the die 7 be firmly coupled to the diebed 9 which in turn must be firmly coupled to the pultrusion apparatus 100. The die 7 can therefore be coupled to the diebed 9 by a variety of means (not shown) such as clamping vices, fastener arrangements, and the like to ensure a rigid and secure connection. In addition, alignment device(s) (not shown) may also be coupled to the die 7 or diebed 9 to correctly align or orient the die 7, to assist with providing a uniformly shaped and formed final product.

Sometimes, when a different end product is desired, or when maintenance of the die 7 is required, the entire pultrusion process must be halted to remove the die 7 from the diebed 9. This requires that the coupling means and performing devices that attach and align the die 7 to the diebed 9 must also be removed. Once a new die 7 is ready, whether that be the same die having undergone maintenance, or a new die with a different internal mould, the entire clamping and alignment process needs to be repeated to couple the new die 7 to the diebed 9. The plurality of continuous lengths of fibres must also be rearranged within the new die 7. This process results in significant down time which increases production time and costs.

However, if instead the diebed 9 itself is made removable, then the diebed 9 may instead be replaced with a new diebed having a new die already coupled and aligned thereto. This would significantly reduce the downtime between product changes or maintenance checks. Further, if the new die 7 coupled to a new diebed 9 is provided on a movable platform, then the movable platform may instead be simply moved into the appropriate position within the pultrusion apparatus 100 also significantly reducing downtime.

Thus, figures 3-8 show an embodiment of a first interchangeable diebed carriage 50. The first interchangeable diebed carriage 50 is also shown along with a pultrusion apparatus 200. The pultrusion apparatus 200 has substantially the same features and functions as the previously described embodiment of the pultrusion apparatus 100, except as described below, with like parts indicated by the addition of 100.

The first interchangeable diebed carriage 50 for a pultrusion apparatus 200 includes a carriage body 51 comprising a diebed 53 for receipt of, or coupled to, a first die 55. The first interchangeable diebed carriage 50 also includes a movement arrangement 57 configured such that the diebed carriage 50 is movable along a support surface 300 to a position within the pultrusion apparatus 200 for use of the first die 55 during a pultrusion process.

As outlined below, in some configurations, the diebed 53 is configured for receipt of, or is couplable to, a plurality of first dies. Figures 3-8 shows three first dies 55 arranged in parallel, as typically used in a pultrusion process to create a plurality of continuous lengths of a pultruded product. However, for ease of reference, only one of those first dies 55 will be referred to in the below description of the first interchangeable diebed carriage 50.

The movement arrangement 57 is shown comprising a plurality of wheels 59. These wheels 59 may be directly rotatably attached to the carriage body 51, may be suspended using appropriate means such as dampers, springs or control arms (not shown), and can in some configurations be pivotal about a vertical axis to allow for steering of the carriage body 51. Alternatively, any other appropriate components can be used to form the movement arrangement 57, such as a track and roller combination, for instance, which may also be suspended, or steerable, as desired.

As such, the first interchangeable diebed carriage 50 is removable from the position within the pultrusion apparatus 200 and replaceable with a second interchangeable diebed carriage (shown in figure 8).

The second interchangeable diebed carriage 70 includes a movement arrangement 77 and a carriage body 72 comprising a diebed 74 coupled to a second die 75, for use of the second die 75 during a pultrusion process. The second interchangeable diebed carriage 70 may comprise all the same features and functions of the first interchangeable diebed carriage 50 as described herein, or may only include a movement arrangement, carriage body and diebed coupled to a second die. In any case, the provision of a plurality of interchangeable diebed carriages allows significant reduction in down time by allowing users of a pultrusion apparatus 200 to simply remove and replace successive diebed carriages with other diebed carriages having similar or different dies, significantly reducing downtime. The first interchangeable diebed carriage 50 can be configured such that as it is moved into the position within the pultrusion apparatus 200, the first interchangeable diebed carriage 50 is oriented to align the first die 55 into position for use of the first die 55 during the pultrusion process.

In other words, the first die 55 may already be optimally aligned and oriented relative to the carriage body 51 such that positioning of the first interchangeable diebed carriage 50, and thus the carriage body 51, within the pultrusion apparatus 200 orients and aligns the first die 55 for immediate use within the pultrusion process, as soon as the plurality of continuous lengths of fibres are arranged within the first die 55 as required.

For instance, the movement arrangement 57 can allow for manual movement of the carriage body 51 by a user or users into the appropriate position and also facilitate correct orientation of the entire carriage body 51, and thus the first die 55, relative to the pultrusion apparatus 200. Alternatively, the movement arrangement 57 may itself be motorised or actuated to steer and orient the first interchangeable diebed carriage 50 into position as required. Orientation of the first interchangeable diebed carriage 50 can also be achieved by a variety of different configurations, as described in further detail below with reference to figures 3-7.

Further, the diebed 53 itself may be configured to orient the first die 55 into position for use of the first die 55 during the pultrusion process. For instance, the diebed 53 may include passive alignment devices, such as manually operated clamps or fastening means, alignment gussets or channels that allow a user to ensure correct alignment, orientation and positioning of the first die 55 relative to the diebed 53. Additionally, or alternatively, the diebed 53 may include active or autonomous alignment devices such as actuated or motorised clamps or turrets that align and orient the first die 55 without the need for user manipulation.

It may also be desired that the diebed 53 be configured to removably receive the first die 55 such that the first die 55 is replaceable with a different die. This can be achieved with any appropriate connecting means such as clamping vices, fasteners and the like. Additionally, or alternatively, the same passive or active alignment devices described above, may also be configured to allow the first die 55 to be removable from the clamp, fastening means, gussets, channels, or actuated/motorised clamps or turrets as desired.

However, as described above, it may also be advantageous if the diebed 53 itself could be swapped out with another diebed 53 having an already pre-aligned/oriented die, to facilitate a further reduction in downtime. Therefore, in some configurations, the carriage body 51 is configured to removably receive the diebed 53 such that the diebed 53 is replaceable with a different diebed coupled to a different die.

For instance, the carriage body 51 may include diebed receiving devices such as manually operated clamps or fastening arrangements, alignment gussets or channels, or autonomous receiving devices such as actuated or motorised clamps, rails and the like that cooperate with features of the diebed 53 to couple the diebed 53 in an optimal alignment and orientation relative to the carriage body 51.

Therefore, since a given die is already aligned or oriented relative to the diebed 53, coupling the diebed 53 to the carriage body 51 orients and aligns the die for immediate use within the pultrusion process, once the first interchangeable diebed carriage 50 is positioned within the pultrusion apparatus 200 and as soon as the plurality of continuous lengths of fibres are arranged within the die as required.

Such configurations provide multiple options for arranging another die during or before downtime. For instance, while the first die 55 of the first interchangeable diebed carriage 50 is in use during the pultrusion process, a second interchangeable diebed carriage can be moved near the pultrusion apparatus 200, and can have a pre-aligned and oriented diebed and second die ready to go. Therefore, once the pultrusion process is halted, the first interchangeable diebed carriage 50 is removed from its position within the pultrusion apparatus 200 and replaced with the second interchangeable diebed carriage.

Alternatively, a second diebed with a second die already coupled thereto may be readied while the first die 55 is in use, such that once the pultrusion process is halted, the diebed 53 carrying the first die 55 is removed from the carriage body 51 and replaced with the second diebed, while the first interchangeable diebed carriage 50 remains in place within the pultrusion apparatus 200.

The above-described removal, replacement, orientation and/or alignment of the first die 55 as well as the removal and replacement of the diebed 53 may both occur prior to the first interchangeable diebed carriage 50 being positioned within the pultrusion apparatus 200, such that the first interchangeable diebed carriage 50 is pre-prepared for use in the pultrusion process, or may otherwise be carried out while the first interchangeable diebed carriage 50 is positioned within the pultrusion apparatus 200. As outlined above, it should also be appreciated that although the above described embodiments of the first interchangeable diebed carriage 50 refer to a singular first die 55, in some configurations, the diebed 53 is configured for receipt of, or is couplable to, a plurality of first dies. Figures 3-8 show three first dies 55 arranged in parallel. The plurality of first dies can include two, three or more first dies receivable by, or coupled to, the diebed 53 in a parallel arrangement. Further, the plurality of first dies may be comprised of substantially identical dies, i.e., multiple first dies forming the same product, or may be comprised of different dies forming different products, or a combination thereof.

Each of these first dies may retain the same features and working principles of the first die 55 in relation to any of the other components of the first interchangeable diebed carriage 50, as described throughout this specification. Each of the first dies may also be oriented, aligned, coupled to, or removed from, the diebed 53 and/or be replaced by a different die, in unison or separately from one another as desired. This applies equally to the second interchangeable diebed carriage and/or the second diebed described above. In some configurations, only a single first die 55 may be used if desired.

In any case, since the polymerization of the resin within the plurality of continuous lengths of impregnated fibres may require appropriate heating, the carriage body 51, the diebed 53, and/or the first die 55 may be provided with an electric connector (not shown) that couples with a respective electric connector of the pultrusion apparatus 200. This may facilitate transfer of electric power to the diebed 53 or first die 55 to heat the first die 55 to the appropriate temperatures.

Further, given the continuous manufacturing nature of a pultrusion process, it may also be desired to transfer information to and from the interchangeable diebed carriage and the appropriate control system of the pultrusion apparatus 200 using said electric connector(s). Such information can include, for example, the type of die coupled to the carriage 50, the length of time in use and the temperature or temperature changes which may assist in autotomising the pultrusion process.

In some configurations, as shown in figures 3-7, the pultrusion apparatus 200 and/or the first interchangeable diebed carriage 50 can include a carriage positioning arrangement 61 configured to position the first interchangeable diebed carriage 50 within the pultrusion apparatus 200. The carriage positioning arrangement 61 can include at least one actuated member 63 configured to move the first interchangeable diebed carriage 50 into the position within the pultrusion apparatus 200.

In the form shown, the actuated member 63 is coupled to the pultrusion apparatus 200 and takes the form of a telescopic ram 65. The telescopic ram 65 can be hydraulically actuated, pneumatically actuated, or electromechanically actuated, to telescopically extend out from the pultrusion apparatus 200 and cooperate with and couple to a surface or engagement feature (not shown) of the interchangeable diebed carriage 50.

Said engagement feature may be a passive component of the carriage body 51, for example a spring-loaded socket that is configured to receive and clamp onto an end of the telescopic ram 65 upon entry into the socket. Alternatively, said engagement feature may be actuated/motorised, such as a clamping mechanism that changes configuration to receive then clamp onto the end of the telescopic ram 65.

Alternatively, instead of a telescopic ram 65, the at least one actuated member 63 may be, for example, a winch and cable device configured to hook onto a tow bar or tow hook of the carriage body 51, or any other suitable mechanism.

In any case, the at least one actuated member 63, once coupled to the first interchangeable diebed carriage 50, will be actuated to move or pull the first interchangeable diebed carriage 50 to the appropriate position within the pultrusion apparatus 200. This is shown in figures 5 and 6, in which the first interchangeable diebed carriage 50 has been engaged by the actuated member 63, then in figures 3 and 4, the actuated member 63 has moved the first interchangeable diebed carriage 50 into position within the pultrusion apparatus 200.

In this way, the first interchangeable diebed carriage 50 may not need to be manually moved by user(s) into position, but may only need to be moved into an approximate location around the pultrusion apparatus 200, with the actuated member 63 configured to couple to and move the first interchangeable diebed carriage 50 from that location into the correct position. This applies equally in instances where the movement arrangement 57 of the first interchangeable diebed carriage 50 is actuated, such that the first interchangeable diebed carriage 50 is self-guiding or self-moving.

Further, while the at least one actuated member 63 can be configured to move the first interchangeable diebed carriage 50 into position, the carriage positioning arrangement 61 can additionally include at least one guiding member 67 configured to align the first interchangeable diebed 50 into position within the pultrusion apparatus 200 as it is moved into the position within the pultrusion apparatus 200.

The at least one guiding member 67 is shown in figures 3-7 in the form of lateral wedges 69 protruding from the pultrusion apparatus 200. As the carriage body 51 approaches the pultrusion apparatus 200, the lateral wedges 69 cooperate with a surface or feature of the interchangeable diebed carriage 50 to guide the carriage body into alignment with the pultrusion apparatus 200. This may be achieved by configuring the lateral wedges 59 with a tapered shape as shown in figures 3-7, such that the spacing between the ends of the lateral wedges 59 further away from the pultrusion apparatus 200 is larger than the spacing between the ends of the lateral wedges 59 proximate or connected to the pultrusion apparatus 200.

For instance, the lateral wedges 69 may cooperate with corresponding angular surfaces (not shown) on both sides of the carriage body 51, the shapes of the wedges 69 and corresponding surfaces thereby guiding alignment of the carriage body 51. Alternatively, the lateral wedges 69 may cooperate with a feature such as mirrored lateral wedges provided on sides of the carriage body 51, or more complex mechanisms such as spring- loaded or resilient toggles that are depressed to more gradually guide the carriage body 51 as it is moved into position.

Further, while the lateral wedges 69 may align the carriage body 51 in the horizonal direction, the at least one guiding member 67 may also align the carriage body 51 in the vertical direction, so that the diebed 53 and first die 55 are at the correct height for use in the pultrusion process. For instance, top and bottom wedges (not shown) may also be provided in addition to lateral wedges 69 to align the height of the carriage body 51 as desired and may comprise the same functions and feature as described above in relation to the lateral wedges 69.

Additionally or alternatively, the carriage positioning arrangement 61 can also be configured such that as the first interchangeable diebed carriage 50 is moved into position within the pultrusion apparatus 200, the movement arrangement 57 of the first interchangeable diebed carriage 50 is elevated above the support surface 300. The support surface 300 can be, for example, the floor of a manufacturing facility, a platform atop which the pultrusion apparatus 200 is arranged, or any other suitable surface. By elevating the movement arrangement 57, e.g. wheels 59, above the support surface 300, it is ensured that the carriage body 51 cannot move across the support surface 300 due to rolling contact between the wheels 59 and said support surface 300.

The component of the carriage positioning arrangement 61 that provides this functionality is at least one elevation member, shown as the ramped platforms 71 provided on the support surface 300 in figure 7. These ramped platforms 71 cooperate with complementary ramps 73 provided at the bottom surface of the carriage body 51, to elevate the movement arrangement 57, or wheels 59, as the carriage body 51 approaches the pultrusion apparatus 200.

Alternatively, if the complementary ramps 73 are not provided i.e., if only the ramped platforms 71 on the support surface 300 are provided, then the ramped platforms 71 may also comprise features that prevent translation of the wheels 59 on the platforms. For instance, the upper surfaces of the ramped platforms 71 may comprise a high- friction material or coating, or a socket that receives a portion of the wheels 59, or any other suitable feature that constrains a position of the movement arrangement 57 depending on the form the movement arrangement 57 takes.

For example, if the movement arrangement 57 instead comprises a track and roller combination, the ramped platforms 71 may instead be replaced with a hinged locking bar protruding from a recess of the support surface 300 that is configured to cooperate with a surface of the tracks to couple onto and lift the movement arrangement 57 as the tracks ride over the locking bar.

Additionally, or alternatively, either of, or both of the at least one actuated member 63 or the at least one guiding member 57 may provide this elevation functionality. For instance, the at least one actuated member 63 may also be actuated to elevate the movement arrangement 57 during or after it has pulled or moved the first interchangeable diebed carriage 50 into position within the pultrusion apparatus 200, or the at least one guiding member 57 can include provisions to elevate the movement arrangement 57 as it aligns the carriage body 51, as described above in relation to the lateral wedges 69 or the top and bottom wedges (not shown).

Further, any of the above described components of the carriage positioning arrangement 61 can also provide a coupling function to rigidly connect the first interchangeable diebed 50 to the pultrusion apparatus 200. For instance, the at least one actuated member 63 and/or the at least one guiding member 67 may comprise a locking or clamping member that engages a surface or feature of either the pultrusion apparatus 200 or the interchangeable diebed carriage 50 to constrain the interchangeable diebed carriage 50 to the pultrusion apparatus 200.

Other features not part of the carriage positioning arraignment 61 may also provide such a function. For instance, the carriage body 51, movement arrangement 57, or even the diebed itself 53 may comprise locking or clamping members, or provisions for receipt of fasteners such a pin and bolt combination that couple and lock the first interchangeable diebed carriage 50 to the pultrusion apparatus 200. In any case, the first interchangeable diebed carriage 50 may be locked to the pultrusion apparatus 200 to ensure adequate resistance against the tension force of the at least one pulling device 103, thereby preventing misalignment or mispositioning of the carriage body 51, the diebed 53 or the first die 55, when in use in a pultrusion process.

Finally, as noted above, since either the pultrusion apparatus 200 and/or the first interchangeable diebed carriage 50 can include the carriage positioning arrangement 61, it is to be understood that the above described features and functions of the carriage positioning arrangement 61 may be provided on either one of, or both of the pultrusion apparatus 200 or the first interchangeable diebed carriage 50.

Thus, the at least one actuated member 63, the at least one guiding member 67 and/or the elevation members comprising the ramped platforms 71 can be provided on one of or both of the apparatus 200 or the diebed carriage 50 to cooperate with a corresponding actuated member 63, guiding member 67 and/or elevation member 71 provided on the other of the pultrusion apparatus 200 or the first interchangeable diebed carriage 50.

For example, an actuated member of the pultrusion apparatus 200 may extend to cooperate with an actuated member of the first interchangeable diebed carriage 50 to move the first interchangeable diebed carriage 50 into position within the pultrusion apparatus 200. Further, a guiding member of the pultrusion apparatus 200 may cooperate with a corresponding guiding member of the first interchangeable diebed carriage 50 to align the first interchangeable diebed carriage 50 into the correct position as it is moved into position within the pultrusion apparatus 200.

The pultrusion apparatus 200 may comprise substantially the same features as the above described embodiment of the pultrusion apparatus 100. In particular, although not shown in figure 8, as shown in figures 3 and 4, the pultrusion apparatus 200 includes an upstream fibre delivery section 101 comprising a fibre source and a resin impregnation device for adding resin to fibre from the fibre source. The pultrusion apparatus 200 also comprises a downstream product forming section comprising at least one pulling device 103 for moving the fibre; and the first interchangeable die bed carriage 50 as described above in relation to figures 3-7.

The first interchangeable diebed carriage 50 is movable to a position within the pultrusion apparatus 200 for use of the first die 55 during a pultrusion process. The first interchangeable diebed carriage 50 is movable into position within the pultrusion apparatus between the upstream fibre delivery section 101 and downstream product forming section. The first interchangeable diebed carriage 50 is also removable from the pultrusion apparatus 200 and replaceable with a second interchangeable diebed carriage 70 comprising a second die 75.

As described above, the second interchangeable diebed carriage 70 may comprise all the same features and functions of the first interchangeable diebed carriage 50.

Further, the upstream fibre delivery section 101 is configured to form a plurality of continuous lengths of impregnated fibres 105, and the at least one pulling device 103 is configured to direct the plurality of continuous lengths of impregnated fibres 105, in a pulling direction indicated by arrow A, from the upstream fibre delivery section 101 through the first die 55 when the first interchangeable diebed carriage 50 is in position within the pultrusion apparatus 200, thereby forming a plurality of continuous lengths of a first pultruded product 111.

The at least one pulling device 103 is also configured to direct the plurality of continuous lengths of impregnated fibres 105 from the upstream fibre delivery section 101 through the second die 75 when the second interchangeable diebed carriage 70 is in position within the pultrusion apparatus 200 thereby forming a plurality of continuous lengths of a second pultruded product (not shown).

The pultrusion apparatus 200 also includes a product severing station 113 configured to sever the plurality of continuous lengths of the first pultruded product 111 thereby forming a plurality of discrete lengths of the first pultruded product (not shown). The product severing station 113 is also configured to sever the plurality of continuous lengths of the second pultruded product thereby forming a plurality of discrete lengths of the second pultruded product (not shown). As such, figure 8 illustrates the beneficial provision of a first interchangeable diebed carriage 50 comprising a first die 55 and a second diebed carriage 70 comprising a second die 75 for use in a pultrusion process using the pultrusion apparatus 200. The pultrusion apparatus of figures 3-8 thereby achieves a significant reduction in downtime whenever a product change or die maintenance is required compared to the standard pultrusion apparatus 100 of figures 1 and 2.

An associated pultrusion method will now be described to illustrate the process that results from the provision of the interchangeable diebed carriage. The method includes the steps of providing a plurality of continuous lengths of impregnated fibres 105 and then directing the plurality of continuous lengths of impregnated fibres 105 through a first die 55 coupled to the first interchangeable diebed carriage 50 thereby forming a plurality of continuous lengths of a first pultruded product 111. The plurality of continuous lengths of the first pultruded product 111 are then directed through a product severing station 113 thereby forming a plurality of discrete lengths of the first pultruded product.

Further steps include then replacing the first interchangeable diebed carriage 50 with a second interchangeable diebed carriage 70 comprising a movement arrangement and a carriage body comprising a diebed coupled to a second die 75, and then directing the plurality of continuous lengths of impregnated fibres 105 through the second die 75 coupled to the second interchangeable diebed carriage 70 thereby forming a plurality of continuous lengths of a second pultruded product.

Finally, the plurality of continuous lengths of the second pultruded product are also directed through the product severing station 113 thereby forming a plurality of discrete lengths of the second pultruded product.

Once more, it should also be appreciated that although the above described embodiments of the second interchangeable diebed carriage 70 refer to a singular second die 75, in some configurations, in some embodiments the second interchangeable diebed carriage 70 comprises, and/or is coupled to, a plurality of second dies. Figure 8 shows three second dies 75 arranged in parallel. The plurality of second dies can include two, three or more second dies receivable by, or coupled to, a second diebed of the second interchangeable diebed carriage 70 in a parallel arrangement. Further, the plurality of second dies may be comprised of substantially identical dies, i.e., multiple second dies forming the same product, or may be comprised of different dies forming different products, or a combination thereof. In some configurations, only a single second die 75 may be used if desired.

Once more, this pultrusion method illustrates the beneficial provision of a first interchangeable diebed carriage 50 comprising a first die 55 and a second diebed carriage 70 comprising a second die 75 for use in a pultrusion apparatus 200.

This method thereby achieves a significant reduction in downtime whenever a product change or die maintenance is required compared to a standard pultrusion method or process. Further, third, fourth or more interchangeable diebed carriages may also be provided and used to the same effect, providing even more reductions in downtime and flexibility as far as the number of and frequency of product changes or maintenance periods.

Such a reduction in downtime is especially beneficial in pultrusion manufacturing facilities that undertake frequent product changes, and therefore require frequent die changes and increased maintenance of the various dies. Further, the embodiments of the interchangeable diebed carriage, the pultrusion apparatus 200, and associated methods described herein provide an otherwise less diverse pultrusion manufacturing facility the means to expand their product range with the provision of more types of dies or even custom dies, since the increased costs associated therewith can at least be partly reduced.

Preferred embodiments of the invention have been described by way of example only and modifications may be made thereto without departing from the scope of the invention.

Claims

1. A first interchangeable diebed carriage for a pultrusion apparatus, the first interchangeable diebed carriage comprising: a carriage body comprising a diebed for receipt of, or coupled to, a first die; and a movement arrangement configured such that the diebed carriage is movable to a position within the pultrusion apparatus for use of the first die during a pultrusion process, wherein the first interchangeable diebed carriage is removable from the position within the pultrusion apparatus and replaceable with a second interchangeable diebed carriage comprising a movement arrangement and a carriage body comprising a diebed coupled to a second die, for use of the second die during a pultrusion process.

2. The first interchangeable diebed carriage of claim 1, wherein the first interchangeable diebed carriage is configured such that as the first interchangeable diebed carriage is moved into the position within the pultrusion apparatus, the first interchangeable diebed carriage is oriented to align the first die into position for use of the first die during the pultrusion process.

3. The first interchangeable diebed carriage of claim 1 or claim 2, wherein the diebed is configured to orient the first die into position for use of the first die during the pultrusion process.

4. The first interchangeable diebed carriage of any one of claims 1 to 3, wherein the carriage body is configured to removably receive the diebed such that the diebed is replaceable with a different diebed coupled to a different die.

5. The first interchangeable diebed carriage of any one of claims 1 to 4, wherein the diebed is configured to removably receive the first die such that the first die is replaceable with a different die.

6. The first interchangeable diebed carriage of any one of claims 1 to 5, wherein the diebed is configured for receipt of, or is couplable to, a plurality of first dies.

7. The first interchangeable diebed carriage of any one claims 1 to 6, wherein the pultrusion apparatus and/or the first interchangeable diebed carriage comprises a carriage positioning arrangement configured to position the first interchangeable diebed carriage within the pultrusion apparatus.

8. The first interchangeable diebed carriage of claim 7, wherein the carriage positioning arrangement comprises at least one actuated member configured to move the first interchangeable diebed carriage into the position within the pultrusion apparatus.

9. The first interchangeable diebed carriage of claim 7 or 8, wherein the carriage positioning arrangement comprises at least one guiding member configured to align the first interchangeable diebed into position within the pultrusion apparatus as it is moved into the position within the pultrusion apparatus.

10. The first interchangeable diebed carriage of any one of claims 7 to 9, wherein the carriage positioning arrangement is configured such that as the first interchangeable diebed carriage is moved into the position within the pultrusion apparatus, the movement arrangement of the first interchangeable diebed carriage is elevated above a support surface.

11. A pultrusion apparatus comprising: an upstream fibre delivery section comprising: a fibre source; a resin impregnation device for adding resin to fibre from the fibre source; and a downstream product forming section comprising: at least one pulling device for moving the fibre; and the first interchangeable die bed carriage of any one of claims 1 to 10; wherein the first interchangeable diebed carriage is movable to a position within the pultrusion apparatus for use of the first die during a pultrusion process, and wherein the first interchangeable diebed carriage is removable from the pultrusion apparatus and replaceable with a second interchangeable diebed carriage comprising a second die.

12. The pultrusion apparatus of claim 11, wherein the upstream fibre delivery section is configured to form a plurality of continuous lengths of impregnated fibres, and wherein the at least one pulling device is configured to direct the plurality of continuous lengths of impregnated fibres from the upstream fibre delivery section through the first die when the first interchangeable diebed carriage is in position within the pultrusion apparatus thereby forming a plurality of continuous lengths of a first pultruded product. The pultrusion apparatus of claim 12, wherein the at least one pulling device is configured to direct the plurality of continuous lengths of impregnated fibres from the upstream fibre delivery section through the second die when the second interchangeable diebed carriage is in position within the pultrusion apparatus thereby forming a plurality of continuous lengths of a second pultruded product. The pultrusion apparatus of claim 12 or claim 13, further comprising a product severing station configured to sever the plurality of continuous lengths of the first pultruded product thereby forming a plurality of discrete lengths of the first pultruded product. The pultrusion apparatus of claim 14 when dependent on claim 13, further comprising a product severing station configured to sever the plurality of continuous lengths of the second pultruded product thereby forming a plurality of discrete lengths of the second pultruded product. The pultrusion apparatus of any one of claims 11 to 15, wherein the second interchangeable diebed carriage comprises a plurality of second dies. A pultrusion method comprising the steps of: providing a plurality of continuous lengths of impregnated fibres; directing the plurality of continuous lengths of impregnated fibres through the first die of the first interchangeable diebed carriage of any one of claims 1 to 10 thereby forming a plurality of continuous lengths of a first pultruded product; replacing the first interchangeable diebed carriage with a second interchangeable diebed carriage comprising a movement arrangement and a carriage body comprising a diebed coupled to a second die; directing the plurality of continuous lengths of impregnated fibres through the second die coupled to the second interchangeable diebed carriage thereby forming a plurality of continuous lengths of a second pultruded product. The pultrusion method of claim 15, further comprising the steps of: directing the plurality of continuous lengths of the first pultruded product through a product severing station thereby forming a plurality of discrete lengths of the first pultruded product; and directing the plurality of continuous lengths of the second pultruded product through the product severing station thereby forming a plurality of discrete lengths of the second pultruded product. The pultrusion method of claim 17 or 18, wherein the diebed of the second interchangeable diebed carriage is coupled to a plurality of second dies.